Connectors for smart windows

ABSTRACT

This disclosure provides connectors for smart windows. A smart window may incorporate an optically switchable pane. In one aspect, a window unit includes an insulated glass unit including an optically switchable pane. A wire assembly may be attached to the edge of the insulated glass unit and may include wires in electrical communication with electrodes of the optically switchable pane. A floating connector may be attached to a distal end of the wire assembly. The floating connector may include a flange and a nose, with two holes in the flange for affixing the floating connector to a first frame. The nose may include a terminal face that present two exposed contacts of opposite polarity. Pre-wired spacers improve fabrication efficiency and seal integrity of insulated glass units. Electrical connection systems include those embedded in the secondary seal of the insulated glass unit.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part of International ApplicationPCT/US2015/014479 (designating the United States), titled “CONNECTORSFOR SMART WINDOWS” and filed on Feb. 4, 2015, which claims priority toand benefit of U.S. Provisional Patent Application No. 61/935,757,titled “CONNECTORS FOR SMART WINDOWS” and filed on Feb. 4, 2014 and U.S.patent application Ser. No. 14/363,769, titled “CONNECTORS FOR SMARTWINDOWS” and filed on Jun. 6, 2014. This application is also acontinuation-in-part of U.S. patent application Ser. No. 14/363,769,titled “CONNECTORS FOR SMART WINDOWS” and filed on Jun. 6, 2014. U.S.patent application Ser. No. 14/363,769 is a national stage applicationunder 35 U.S.C. § 371 to International PCT Application No.PCT/US12/68950 (designating the United States), titled “CONNECTORS FORSMART WINDOWS” and filed on Dec. 11, 2012, which claims priority to andbenefit of U.S. patent application Ser. No. 13/326,168 (now U.S. Pat.No. 8,643,933), titled “CONNECTORS FOR SMART WINDOWS” and filed on Dec.14, 2011. This application is also a continuation-in-part of U.S. patentapplication Ser. No. 14/823,969, titled “SPACERS FOR INSULATED GLASSUNITS” and filed on Aug. 11, 2015, which is a continuation applicationof U.S. patent application Ser. No. 14/152,873 (now U.S. Pat. No.9,158,173), titled “SPACERS FOR INSULATED GLASS UNITS” and filed on Jan.10, 2014. U.S. patent application Ser. No. 14/152,873 is a continuationof U.S. patent application Ser. No. 13/312,057 (now U.S. Pat. No.8,711,465), titled “SPACERS FOR INSULATED GLASS UNITS” and filed on Dec.6, 2011, which claims priority to U.S. Provisional Patent ApplicationNo. 61/421,154, titled “IMPROVED SEPARATORS FOR INSULATED GLASS UNITS”and filed on Dec. 8, 2010 and to U.S. Provisional Patent Application No.61/435,914, titled “SEPARATORS FOR INSULATED GLASS UNITS” and filed onJan. 25, 2011. All of these applications are hereby incorporated byreference in their entirety and for all purposes.

FIELD

The disclosed embodiments relate generally to optically switchabledevices, and more particularly to connectors for optically switchablewindows.

BACKGROUND

Various optically switchable devices are available for controllingtinting, reflectivity, etc. of window panes. Electrochromic devices areone example of optically switchable devices generally. Electrochromismis a phenomenon in which a material exhibits a reversibleelectrochemically-mediated change in an optical property when placed ina different electronic state, typically by being subjected to a voltagechange. The optical property being manipulated is typically one or moreof color, transmittance, absorbance, and reflectance. One well knownelectrochromic material is tungsten oxide (WO3). Tungsten oxide is acathodic electrochromic material in which a coloration transition,transparent to blue, occurs by electrochemical reduction.

Electrochromic materials may be incorporated into, for example, windowsfor home, commercial, and other uses. The color, transmittance,absorbance, and/or reflectance of such windows may be changed byinducing a change in the electrochromic material, that is,electrochromic windows are windows that can be darkened or lightenedelectronically. A small voltage applied to an electrochromic device ofthe window will cause it to darken; reversing the voltage causes it tolighten. This capability allows for control of the amount of light thatpasses through the window, and presents an enormous opportunity forelectrochromic windows to be used not only for aesthetic purposes butalso for energy-savings.

With energy conservation being foremost in modern energy policy, it isexpected that growth of the electrochromic window industry will berobust in the coming years. An important aspect of electrochromic windowengineering is how to integrate electrochromic windows into new andexisting (retrofit) applications. Of particular import is how to deliverpower to the electrochromic glazings through framing and relatedstructures.

SUMMARY

Connectors for optically switchable devices, including electrochromicdevices, are disclosed herein. A connector and an electrochromic devicemay be associated with or incorporated in an insulated glass unit (IGU),a window assembly, or a window unit, in some embodiments.

In one embodiment, a window unit includes an IGU including an opticallyswitchable pane. A wire assembly is attached to an edge of the IGU andincludes wires in electrical communication with distinct electrodes ofthe optically switchable pane. A floating connector is attached to thedistal end of the wire assembly, with the floating connector beingelectrically coupled to the optically switchable pane. The floatingconnector includes a flange and a nose extending from the flange by adistance approximately equal to a thickness of a first frame in whichthe IGU is to be mounted. The nose includes a terminal face presenting,at least, two exposed contacts of opposite polarities. Other contactsmay be present, e.g., for communication to a logic circuit in the windowunit. The floating connector further includes two holes in the flangefor affixing the floating connector to the first frame. The two holes inthe flange are arranged with respect to the nose such that the nose iscloser to one of the holes than the other, thereby requiring that thetwo exposed contacts be arranged in a defined orientation when thefloating connector is affixed to the first frame. In other embodiments,the floating connector includes an asymmetric element in the shape ofthe nose and/or the flange that permits installation in only one way.

In another embodiment, a window assembly includes an IGU including anoptically switchable pane. A first connector is mounted to the IGU in asealant of the IGU. The first connector includes exposed contactselectrically coupled to leads extending from the optically switchablepane and through the IGU, e.g., around the perimeter of a spacer of theIGU and to the first connector. The first connector further includes afirst ferromagnetic element which itself may be magnetized. A wireassembly is configured to be detachably mounted to the IGU through thefirst connector. The wire assembly includes at least two wires extendingfrom and electrically coupled to a second connector. The secondconnector includes a surface having contacts and the surface is shapedfor mechanical engagement to the first connector. The second connectorfurther includes a second ferromagnetic element, which itself may bemagnetized. At least one of the first and second ferromagnetic elementsis magnetized such that the first and second connectors may magneticallyengage one another to provide electrical communication between theirrespective contacts.

In another embodiment, a window system includes a first IGU. The firstIGU includes a first optically switchable pane and a first connector inelectrical communication with electrodes of the first opticallyswitchable pane. A first coupling unit includes two connectors linked bya flexible ribbon cable, with a first of the two connectors beingconfigured to mate with the first connector.

Certain embodiments include pre-wired spacers, electrical connectionsystems for IGUs that include at least one optical device and the IGUsthat include such systems. In some embodiments, onboard controllers arepart of the electrical connection systems. Many components of theelectrical connection systems may be embedded within the secondary seal.Electrical connection systems described herein may include componentsfor providing electrical powering to the IGU at virtually any locationabout the perimeter of the IGU. In this way, the installer in the fieldis given maximum convenience and flexibility when installing IGUs havingoptical devices, e.g. electrochromic devices.

Certain embodiments pertain to an electrical connection system for asliding door. The electrical connection system comprises a guide and ashuttle. The guide comprises a recess within which pass one or morewires for electrical communication between at least a power source andan optically switchable device in the sliding door or window. The guidefurther comprises an outer surface and a lengthwise slot in the outersurface. The shuttle is configured to couple to the sliding door orwindow and slideably engage with the lengthwise slot in the guide. Theshuttle is further configured to pass the one or more wires from thesliding door or window, through a body of the shuttle into the recess inthe guide, wherein during movement of the sliding door or window, theone or more wires are protected from interaction with one or more movingcomponents. In some cases, electrical connection system a flexiblemember affixed at one end to the shuttle. The one or more wires arecoupled to the flexible member and the flexible member comprises a bendportion allowing the flexible member to pass back over itself and residesubstantially parallel to the length of, and inside, the guide. In oneexample, the one or more wires are a ribbon cable and the flexiblemember is a spring steel tape. In another example, the flexible memberis a chain guide made of a non-electrically conducting material, and theone or more wires reside within the body of the chain guide.

Certain embodiments pertain to an electrical connection system for asliding door or window where the electrical connection system comprisesa frame bracket configured to couple to the sliding door or window and abase bracket configured to couple to a header of the sliding window ordoor, or to a base rail. The frame bracket and the base bracket areconfigured to house opposing ends of an IGU connector cable. In oneembodiment, the electrical connection system further comprises a chainguide configured to house a middle portion of the IGU connector cablebetween the frame bracket and the base bracket.

These and other features and advantages will be described in furtherdetail below, with reference to the associated drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of a voltage profile for driving optical statetransitions for an electrochromic device.

FIG. 2 is a cross-sectional schematic of an electrochromic device.

FIG. 3 shows examples of the operations for fabricating an IGU includingan electrochromic pane and incorporating the IGU into a frame.

FIG. 4 shows an example of a manner in which an IGU including anelectrochromic pane may be transported during fabrication and/or testingof the IGU.

FIG. 5A is a schematic diagram of an IGU including an electrochromicpane and an associated wire assembly.

FIG. 5B shows an example of the manner in which an IGU including anelectrochromic pane may be transported during fabrication and/or testingof the IGU.

FIG. 5C depicts a first connector and second connector, each having twoferromagnetic elements.

FIG. 5D depicts an IGU with two or more redundant connectors embedded inthe secondary seal.

FIG. 6 shows examples of schematic diagrams of an IGU including anelectrochromic pane in a frame with a floating connector installed inthe frame.

FIG. 7 shows examples of schematic diagrams of a window unitincorporating an IGU including an electrochromic pane with detail of aconnection configuration for powering the IGU.

FIG. 8 shows examples of schematic diagrams of a window unitincorporating IGUs including electrochromic panes with detail of aconnection configuration for powering the IGUs.

FIGS. 9A-9D show examples of schematic diagrams of IGUs and window unitswith ribbon cable connector embodiments as described herein.

FIG. 9E shows an example of a schematic diagram of a sliding door with aribbon cable connector system.

FIG. 9F shows an example of a schematic diagram of a sliding door withanother ribbon cable connector system.

FIGS. 9G and 9H depict perspective views of a power/communications cablemanagement system for movable doors or windows.

FIGS. 10A and 10B include schematic diagrams of an IGU with a frame thatmay serve as both as a secondary sealing element and an electricalconnector for an electrochromic pane of the IGU.

FIGS. 11A-E depict aspects of IGU wiring schemes.

FIGS. 12A-D depict aspects of pre-wired spacers.

FIGS. 13A and 13B depict aspects of a pre-wired spacer.

FIGS. 14A and 14B depict aspects of another pre-wired spacer.

FIG. 15 is a cross-sectional perspective of a pre-wired spacer includingelectrical connection about the perimeter of the spacer andthrough-spacer wiring.

FIG. 16A is a cross-sectional perspective of another pre-wired spacerincluding electrical connection about the perimeter of the spacer andthrough-spacer wiring.

FIGS. 16B-C show aspects of a particular embodiment in accord with thepre-wired spacer described in relation to FIG. 16A.

FIG. 16D shows alternative piercing-type pin connectors in accord withthe embodiments described in relation to FIGS. 16A-C.

FIG. 17A depicts an electrical connection system where ribbon cable isused in the secondary seal in conjunction with piercing-type connectorsas described herein.

FIG. 17B depicts an electrical connection system where ribbon cable isused in the secondary seal, and pin and socket connectors are configuredin the secondary seal as well.

FIG. 18A depicts an electrochromic window controller havingpiercing-type pin connectors as described herein.

FIG. 18B depicts a close up perspective of a controller as described inrelation to FIG. 18A.

DETAILED DESCRIPTION

It should be understood that while the disclosed embodiments focus onelectrochromic (EC) windows (also referred to as smart windows), theconcepts disclosed herein may apply to other types of switchable opticaldevices, including liquid crystal devices, suspended particle devices,and the like. For example, a liquid crystal device or a suspendedparticle device, instead of an electrochromic device, could beincorporated in any of the disclosed embodiments.

An IGU can include the transparent portion of a “window.” In thefollowing description, an IGU may include two substantially transparentsubstrates, for example, two panes of glass, where at least one of thesubstrates includes an electrochromic device disposed thereon, and thesubstrates have a separator (or “spacer”) disposed between them. One ormore of these substrates may itself be a structure having multiplesubstrates. An IGU is typically hermetically sealed, having an interiorregion that is isolated from the ambient environment. A window assemblymay include an IGU, electrical connectors for coupling the one or moreelectrochromic devices of the IGU to a window controller, and a framethat supports the IGU and related wiring.

In order to orient the reader to embodiments for delivering power to oneor more electrochromic devices in an IGU and/or window assembly, anexemplary description of a powering curve for transitioning anelectrochromic window is presented.

FIG. 1 shows an example of a voltage profile for driving optical statetransitions for an electrochromic device. The magnitude of the DCvoltages applied to an electrochromic device may depend in part on thethickness of the electrochromic stack of the electrochromic device andthe size (e.g., area) of the electrochromic device. A voltage profile,100, includes the following sequence: a negative ramp, 102, a negativehold, 103, a positive ramp, 104, a negative hold, 106, a positive ramp,108, a positive hold, 109, a negative ramp, 110, and a positive hold,112. Note that the voltage remains constant during the length of timethat the device remains in its defined optical state, i.e., in negativehold 106 and positive hold 112. Negative ramp 102 drives the device tothe colored state and negative hold 106 maintains the device in thecolored state for a desired period of time. Negative hold 103 may be fora specified duration of time or until another condition is met, such asa desired amount of charge being passed sufficient to cause the desiredchange in coloration, for example. Positive ramp 104, which increasesthe voltage from the maximum in negative voltage ramp 102, may reducethe leakage current when the colored state is held at negative hold 106.

Positive ramp 108 drives the transition of the electrochromic devicefrom the colored to the bleached state. Positive hold 112 maintains thedevice in the bleached state for a desired period of time. Positive hold109 may be for a specified duration of time or until another conditionis met, such as a desired amount of charge being passed sufficient tocause the desired change in coloration, for example. Negative ramp 110,which decreases the voltage from the maximum in positive ramp 108, mayreduce leakage current when the bleached state is held at positive hold112.

Further details regarding voltage control algorithms used for drivingoptical state transitions in an electrochromic device may be found inU.S. patent application Ser. No. 13/049,623 (now U.S. Pat. No.8,254,013), titled “CONTROLLING TRANSITIONS IN OPTICALLY SWITCHABLEDEVICES,” filed Mar. 16, 2011, which is hereby incorporated by referencein its entirety.

To apply voltage control algorithms, there may be associated wiring andconnections to the electrochromic device being powered. FIG. 2 shows anexample of a cross-sectional schematic drawing of an electrochromicdevice, 200. Electrochromic device 200 includes a substrate, 205. Thesubstrate may be transparent and may be made of, for example, glass. Afirst transparent conducting oxide (TCO) layer, 210, is on substrate205, with first TCO layer 210 being the first of two conductive layersused to form the electrodes of electrochromic device 200. Electrochromicstack 215 may include (i) an electrochromic (EC) layer, (ii) anion-conducting (IC) layer, and (iii) a counter electrode (CE) layer toform a stack in which the IC layer separates the EC layer and the CElayer. Electrochromic stack 215 is sandwiched between first TCO layer210 and a second TCO layer, 220, TCO layer 220 being the second of twoconductive layers used to form the electrodes of electrochromic device200. First TCO layer 210 is in contact with a first bus bar, 230, andsecond TCO layer 220 is in contact with a second bus bar, 225. Wires,231 and 232, are connected to bus bars 230 and 225, respectively, andform a wire assembly (not shown) which terminates in a connector, 235.Wires of another connector, 240, may be connected to a controller thatis capable of effecting a transition of electrochromic device 200, e.g.,from a first optical state to a second optical state. Connectors 235 and240 may be coupled, such that the controller may drive the optical statetransition for electrochromic device 200.

Further details regarding electrochromic devices may be found in U.S.patent application Ser. No. 12/645,111, titled “FABRICATION OF LOWDEFECTIVITY ELECTROCHROMIC DEVICES,” filed Dec. 22, 2009. Furtherdetails regarding electrochromic devices may also be found in U.S.patent application Ser. No. 12/645,159, filed Dec. 22, 2009, U.S. patentapplication Ser. No. 12/772,055 (now U.S. Pat. No. 8,300,298) filed Apr.30, 2010, U.S. patent application Ser. No. 12/814,277 filed Jun. 11,2010, and U.S. patent application Ser. No. 12/814,279 filed Jun. 11,2010, each titled “ELECTROCHROMIC DEVICES;” each of the aforementionedare hereby incorporated by reference in their entireties.

In accordance with voltage algorithms and associated wiring andconnections for powering an electrochromic device, there are alsoaspects of how the wired electrochromic glazing is incorporated into anIGU and how the IGU is incorporated into, e.g., a frame. FIG. 3 showsexamples of the operations for fabricating an IGU, 325, including anelectrochromic pane, 305, and incorporating the IGU 325 into a frame,327. Electrochromic pane 305 has an electrochromic device (not shown,but for example on surface A) and bus bars, 310, which provide power tothe electrochromic device, is matched with another glass pane, 315. Theelectrochromic pane may include, for example, an electrochromic devicesimilar to the electrochromic device shown in FIG. 2, as describedabove. In some embodiments, the electrochromic device is solid state andinorganic.

During fabrication of IGU 325, a separator, 320 is sandwiched in betweenand registered with glass panes 305 and 315. IGU 325 has an associatedinterior space defined by the faces of the glass panes in contact withseparator 320 and the interior surfaces of the separator. Separator 320may be a sealing separator, that is, the separator may include a spacerand sealing material (primary seal) between the spacer and each glasspane where the glass panes contact the separator. A sealing separatortogether with the primary seal may seal, e.g. hermetically, the interiorvolume enclosed by glass panes 305 and 315 and separator 320 and protectthe interior volume from moisture and the like. Once glass panes 305 and315 are coupled to separator 320, a secondary seal may be applied aroundthe perimeter edges of IGU 325 in order to impart further sealing fromthe ambient environment, as well as further structural rigidity to IGU325. The secondary seal may be a silicone based sealant, for example.

IGU 325 may be wired to a window controller, 350, via a wire assembly,330. Wire assembly 330 includes wires electrically coupled to bus bars310 and may include other wires for sensors or for other components ofIGU 325. Insulated wires in a wire assembly may be braided and have aninsulated cover over all of the wires, such that the multiple wires forma single cord or line. In some cases, the wire assembly may include a“pigtail” connector as described herein. IGU 325 may be mounted in frame327 to create a window assembly, 335. Window assembly 335 is connected,via wire assembly 330, to window controller, 350. Window controller 350may also be connected to one or more sensors in frame 327 with one ormore communication lines, 345. During fabrication of IGU 325, care mustbe taken, e.g., due to the fact that glass panes may be fragile but alsobecause wire assembly 330 extends beyond the IGU glass panes and may bedamaged. An example of such a scenario is depicted in FIG. 4.

FIG. 4 shows an example of the manner in which an IGU including anelectrochromic pane may be transported during the fabrication processfor the IGU. As shown in FIG. 4, IGUs, 402 and 404, may be transportedand handled on a transport system, 400, in a manner in which an IGUrests on its edge. For example, transport system 400 may include anumber of rollers such that IGUs may easily be translated along anassembly or testing line. Handling an IGU in a vertical manner (i.e.,with the IGU resting on its edge) may have the advantage of the IGUhaving a smaller footprint on a manufacturing floor. Each IGU mayinclude a wire assembly, 412, with a connector (e.g., pigtail connector)that provides electrical contact to the bus bars and the electrochromicstack in each IGU. The wire assembly may be about 12 inches long suchthat the wire does not interfere with transport system 400, e.g., whenthe IGU vertical dimension as it rests on transport system 400 is about12 inches or more. The wire assembly also may be offset from an edge ofthe IGU by about 3 inches, e.g., to ensure that when installed in aframe the wires do not interfere with blocks or other means of securingthe IGU in the frame. During transport on transport system 400, the wireassembly, although sized to avoid contact with transport system 400, maycatch on other features of a fabrication facility or be inadvertentlyheld while the IGU is still moving along transport system 400. When thewire assembly is permanently attached to the IGU as shown in FIGS. 3 and4, the wire assembly may be inadvertently detached from the IGU orotherwise damaged. This may include damaging the wiring within thesecondary seal of the IGU. When this happens, the entire IGU may need tobe replaced. Since typically the electrochromic glazing(s) of the IGUare the most expensive feature, it is unacceptably costly to dispose ofthe entire IGU as a result of damaging the wiring component of the IGUassembly due to external portions of the wiring. Embodiments describedherein avoid such a result.

FIG. 5A is a schematic diagram of an IGU, 500, including anelectrochromic pane, 505, and an associated wire assembly, 530. IGU 500includes electrochromic pane 505 which includes bus bars, 515, which arein electrical communication with an electrochromic device, 517 (for anexemplary cross-section see FIG. 2). Electrochromic pane 505 is matchedwith another pane (not shown) and attached to the other pane with aseparator, 520 (indicated by the dotted lines). The area ofelectrochromic pane 505 outside of separator 520 is a secondary sealingarea, while electrochromic device lies within the perimeter of separator520 (which forms the primary seal against the glass panes of the IGU).In the assembled IGU, the secondary sealing area is typically filledwith a sealing compound (as described in relation to FIG. 3) to form asecondary seal. Wires, 522 and 523, are connected to bus bars 515 andextend through IGU 500 from bus bars 515, through or under spacer 520,and within the secondary seal to a first connector, 525. Wires 522 and523 may be positioned such that they do not appear in the viewableregion of the panes. For example, the wires may be enclosed in thesealing separator or the secondary seal as depicted. In someembodiments, and as depicted, first connector 525 may be housedsubstantially within the secondary seal. For example, first connector525 may be surrounded by the secondary sealant on all sides except forthe face of first connector 525 having two pads, 527. The firstconnector may be housed substantially within the secondary seal indifferent manners. For example, in some embodiments, the first connectormay be housed substantially within the secondary seal and be recessedrelative to the edges of the glass panes. In some embodiments, firstconnector 525 may be housed substantially within the secondary seal andprotrude beyond the edges of the glass panes. In other embodiments,first connector 525 may itself form part of the secondary seal, e.g., bysandwiching between the glass panes with sealant disposed between itselfand the glass panes.

As noted above, first connector 525 includes two pads 527. The two padsare exposed and provide electrical contact to wires 522 and 523. In thisexample, first connector 525 further includes a ferromagnetic element,529. Wire assembly 530 includes a second connector, 535, configured tomate with and provide electrical communication with pads 527. Secondconnector 535 includes a surface having two pads, 540, that provideelectrical contact to wires, 545, of the wire assembly. Second connector535 further includes a ferromagnetic element, 550, configured toregister and mate with ferromagnetic element 529 of the first connector.

Pads 540 of second connector 535 are configured or shaped for mechanicaland electrical contact with pads 527 of first connector 525. Further, atleast one of ferromagnetic elements 529 of first connector 525 or 550 ofsecond connector 535, respectively, may be magnetized. With at least oneof ferromagnetic elements 529 or 550 being magnetized, first connector525 and second connector 535 may magnetically engage one another andprovide electrical communication between their respective pads. Whenboth ferromagnetic elements are magnetized, their polarity is oppositeso as not to repel each other when registered. A distal end (not shown)of the wire assembly 530 may include terminals, sometimes provided in aplug or socket, that allow the wire assembly to be connected to a windowcontroller. In one embodiment, a distal end of wire assembly 530 includea floating connector, e.g., as described in relation to FIGS. 6 and 7.

In one embodiment, rather than a pad to pad contact (e.g., 527 to 540 asin FIG. 5A) for the first and second connectors, a pad to spring-typepin configuration is used. That is, one connector has a pad electricalconnection and the other connector has a corresponding spring-type pin,or “pogo pin”; the spring-type pin engages with the pad of the otherconnector in order to make the electrical connection. In one embodiment,where ferromagnetic elements are also included, the magnetic attractionbetween the ferromagnetic elements of the first and second connectors issufficiently strong so as to at least partially compress the springmechanism of the pogo pin so as to make a good electrical connectionwhen engaged. In one embodiment, the pads and corresponding pogo pinsare themselves the ferromagnetic elements.

In some embodiments, first connector 525, second connector 535, or theterminals or connector at the distal end of the wire assembly (e.g. afloating connector) may include a memory device and/or an integratedcircuit device. The memory device and/or integrated circuit device maystore information for identifying and/or controlling electrochromic pane505 in IGU 500. For example, the device may contain a voltage andcurrent algorithm or voltage and current operating instructions fortransitioning electrochromic pane 505 from a colored stated to ableached state or vice versa. The algorithm or operating instructionsmay be specified for the size, shape, and thickness of electrochromicpane 505, for example. As another example, the device may containinformation that identifies the shape or size of electrochromic pane 505to a window controller such that electrochromic pane 505 may operate inan effective manner. As yet another example, the device may containinformation specifying a maximum electric signal and a minimum electricsignal that may be applied to electrochromic pane 505 by a windowcontroller. Specifying maximum and minimum electric signals that may beapplied to the electrochromic pane may help in preventing damage to theelectrochromic pane.

In another example, the memory and/or integrated circuit device maycontain cycling data for the electrochromic device to which it isconnected. In certain embodiments, the memory and/or integrated circuitdevice includes part of the control circuitry for the one or moreelectrochromic devices of the IGU. In one embodiment, individually, thememory and/or integrated circuit device may contain information and/orlogic to allow identification of the electrochromic device architecture,glazing size, etc., as described above, e.g., during a testing orinitial programming phase when in communication with a controller and/orprogramming device. In one embodiment, collectively, the memory and/orintegrated circuit device may include at least part of the controllerfunction of the IGU for an external device intended as a controlinterface of the installed IGU.

Further, in embodiments in which first connector 525 includes the memorydevice and/or the integrated circuit device, damage to theelectrochromic pane may be prevented because the device is part of IGU500. Having the maximum and minimum electric signals that may be appliedto electrochromic pane 505 stored on a device included in firstconnector 525 means that this information will always be associated withIGU 500. In one example, a wiring assembly as described herein includesfive wires and associated contacts; two of the wires are for deliveringpower to the electrodes of an electrochromic device, and the remainingthree wires are for data communication to the memory and/or integratedcircuit device.

Wire assembly 530 described with respect to FIG. 5A may be easilyattachable to, and detachable from, IGU 500. Wire assembly 530 also mayaid in the fabrication and handling of an IGU because wire assembly 530is not permanently attached to the IGU and will therefore not interferewith any fabrication processes. This may lower the manufacturing costsfor an IGU. Further, as noted above, in some IGUs that include wireassemblies that are permanently attached to the IGU, if the wireassembly becomes damaged and/or separated from the IGU, the IGU may needto be disassembled to reconnect the wire assembly or the IGU may need tobe replaced. With a detachable wire assembly, an IGU may be installedand then the wire assembly attached, possibly precluding any damage tothe wire assembly. If a wire assembly is damaged, it can also be easilyreplaced because it is modular.

Additionally, the detachable wire assembly allows for the replacement orthe upgrade of the wire assembly during the installed life of theassociated IGU. For example, if the wire assembly includes a memory chipand/or a controller chip that becomes obsolete or otherwise needsreplacing, a new version of the assembly with a new chip can beinstalled without interfering with the physical structure of the IGU towhich it is to be associated. Further, different buildings may employdifferent controllers and/or connectors that each require their ownspecial wire assembly connector (each of which, for example, may have adistinct mechanical connector design, electrical requirements, logiccharacteristics, etc.). Additionally, if a wire assembly wears out orbecomes damaged during the installed life of the IGU, the wire assemblycan be replaced without replacing the entire IGU.

Another advantage of a detachable wire assembly is shown in FIG. 5B.FIG. 5B is a schematic diagram of an IGU 500 on a transport system 400and an associated wire assembly. The IGU 500 includes an electrochromicpane and a connector. The transport system 400 may include a number ofrollers such that IGU 500 may easily be moved, as described above. Theportion of transport system 400 shown in FIG. 5B may reside in a testingregion of the manufacturing floor, for example, after the IGU isfabricated. With IGU 500 including a connector and a wire assembly 530with a connector capable of being magnetically coupled to one another asdescribed in FIG. 5A, IGU 500 may be easily tested. For example, testingof the IGU may be performed automatically by dropping wire assembly 530including a connector that includes a ferromagnetic element on to anedge of the IGU. The connector of the wire assembly may connect with theconnector of the IGU, with little or no physical alignment needed, e.g.,due to arrangement of one or more ferromagnetic elements in the matingconnectors. For example, the testing connector end may simply be danglednear the IGU; the registration and connection between the connectorsbeing accomplished by magnetic attraction and alignment making it “snap”into place automatically. The IGU may then be tested, for example, by atesting controller coupled to the other end of the wire assembly 530.Testing may include, for example, activating the electrochromic pane andassessing the electrochromic pane for possible defects. The wireassembly may then be removed from the IGU by a force sufficient toovercome the magnetic attraction between the two connectors. In certainembodiments, the external connector may require appropriate flexiblesupports to prevent the wiring to the external connector fromexperiencing the stress of pulling the connectors apart. The wireassembly may then be ready to engage the next IGU moving along themanufacturing line.

In certain embodiments, each of the first and second connectors includesat least two ferromagnetic elements. In a specific embodiment, each ofthe first and second connectors includes two ferromagnetic elements. A“double” magnetic contact allows for more secure connections. Magnetssuch as neodymium based magnets, e.g., comprising Nd2Fe14B, are wellsuited for this purpose because of their relatively strong magneticfields as compared to their size. As described above, the twoferromagnetic elements may be part of the electrical pads, or not. Inone embodiment, the two ferromagnetic elements in each of the first andthe second connectors are themselves magnets, where the poles of themagnets of each of the first and second connectors that are proximatewhen the connectors are registered, are opposite so that the respectivemagnets in each of the first and second connectors attract each other.

FIG. 5C depicts a first connector (IGU and wiring to the first connectornot shown), 525 a, having two magnets, 560, one with the positive poleexposed and one with the negative pole exposed. The surfaces ofelectrical contacts, 527 a, are also depicted. A second connector, 535a, has corresponding magnets where the poles facing the exposed poles ofmagnets 560 are opposite so as to attract magnets 560. Second connectoralso has wires, 545, that lead to a power source such as a controller(electrical pads on connector 535 a are not depicted). Using such aconnector configuration assures that the electrical connections (thepads in this example) will align correctly due to the magnetic polesattracting only when the opposite poles are proximate each other. In oneembodiment, this arrangement is used where the pad-to-pad orpad-to-pogo-pin electrical connections are so magnetized and poles soconfigured.

When installing an IGU in some framing systems, e.g., a window unit orcurtain wall where multiple IGUs are to be installed in proximity, it isuseful to have flexibility in where the electrical connection is made toeach IGU. This is especially true since typically the electrochromicglazing of the IGUs is always placed on the outside of the installation,facing the external environment of the installation. Given thisconfiguration, having the connectors in the same position within thesecondary seal of the IGUs of the installation requires much more wiringto the controller. However, for example, if the electrical connectors inthe IGUs (as described herein) can be positioned more proximate to eachother, then less wiring is needed from the IGU to the framing system inwhich the IGUs are installed. Thus, in some embodiments, IGU 500 mayinclude more than one first connector 525, that is, redundant connectorsare installed. For example, referring to FIG. 5D, an IGU 590 mightinclude not only a first connector 525 at the upper right hand side, butalso (as indicated by the dotted line features) another connector at thelower left hand side or at the lower right hand side or the upper lefthand side or in the top or bottom portion of the IGU. In this example,the connectors are all within the secondary seal. The exact position oneach edge is not critical; the key is having more than one connectorthat feeds the same electrochromic device so that when installing theIGU, there is flexibility in where to attach the external connector tothe IGU. When IGU 590 is mounted in a frame holding 2, 4, 6, or moreIGUs similar to IGU 590, for example, having multiple first connectorsincluded within each IGU 590 allows for more convenient routing of thewires (e.g., wires 545 as in FIG. 5A associated with each wire assembly530) in the frame due to the flexibility of having multiple redundantfirst connectors to which the second connector may be coupled. In oneembodiment, the IGU has two first connectors, in another embodimentthree first connectors, in yet another embodiment four first connectors.In certain embodiments there may be five or six first connectors.Although the number of connectors may impact production costs, thisfactor may be more than compensated for by the higher degree offlexibility in installation, e.g., in an expensive and sophisticatedcurtain wall installation where volume to accommodate wiring is oftenlimited and installing multiple first connectors during fabrication isrelatively easy.

In some embodiments, the IGU, e.g. 500 or 590, may include twoelectrochromic panes. In these embodiments, the first connector mayinclude four pads (or corresponding pad to pin contacts) to providecontacts to the bus bars of each of the electrochromic panes (i.e., eachelectrochromic pane would include at least two bus bars). Additionalpads for control and communication with the electrochromic device and/oronboard controller may also be included, e.g., four pads for bus barwiring and three additional pads for communication purposes. Onboardcontrollers, e.g. where the controller components are integrated withinthe secondary seal of the IGU, are described in U.S. Pat. No. 8,213,074,titled “Onboard Controller for Multistate Windows,” which is herebyincorporated by reference in its entirety. Likewise, second connector535 would include four pads to provide electrical contact to wires ofthe wire assembly. In other embodiments, each electrochromic pane mayhave its own first connector, or two or more redundant first connectors.Further description of an IGU that includes two or more electrochromicpanes is given in U.S. patent application Ser. No. 12/851,514 (now U.S.Pat. No. 8,270,059), titled “MULTI-PANE ELECTROCHROMIC WINDOWS,” filedAug. 5, 2010, which is hereby incorporated by reference in its entirety.

Certain embodiments include connectors that are external to the IGU andprovide electrical communication from a framing structure to the IGU(either directly wired to the IGU or wired to a first and secondconnector assembly as described above). FIG. 6 shows examples ofschematic diagrams of a window assembly, 600, including an IGU, 610,which includes an electrochromic pane. IGU 610 resides in a frame, 605.A connector, 620, is wired to IGU 610, and as installed attached to aframe 605; at least part of connector 620 (the nose, infra) passesthrough an aperture in frame 605. FIG. 6 includes a top-down schematicdiagram (top left, looking at window assembly 600 from a major face, butwith some aspects missing so as to show internal detail of the assembly)as well as a cross-section (bottom left) B of window assembly 600. Thecross-section B is indicated by cut B on the top-down diagram. Dashedline 607 indicates the front edge of frame 605 (behind the IGU asdepicted); the portion of IGU 610 within dashed line 607 corresponds tothe viewable area of IGU 610 that one would see when the frame isassembled, i.e., that which would function as the window. Glazing blocks615 between IGU 610 and frame 605 serve to support IGU 610 within frame605. Glazing blocks 615 may be compliant to account for differences inthe coefficients of thermal expansion between frame 605 and IGU 610. Forexample, the glazing blocks 615 may be a foam material or a polymericmaterial. Framing material, 625, holds IGU 610 against frame 605. Notethat framing material 625 is not shown in the top-down schematic ofwindow assembly 600. Note also that IGU 610 may be in contact with frame605 and framing material 625 on each face, respectively, as shown butthere may also be some sealant between the glass and the framingmaterial. The cross section shows that this IGU contains two glazingsseparated by spacers.

IGU 610 includes a wire assembly 617 including at least two wireselectrically coupled to the two bus bars (not shown) of anelectrochromic device (not shown) on the electrochromic pane of the IGU.Note that wire assembly 617 is not shown in the cross section of windowassembly 600. The wires of wire assembly 617 terminate at a floatingconnector 620 at a distal end of the wire assembly. Floating connector620 includes two female sockets that are electrically coupled to thewires. Further details regarding embodiments of floating connectors aregiven below with respect to FIG. 7. A fixed connector, 630, includingtwo male pins may be plugged into floating connector 620. The fixedconnector may be fixed to a frame or building in which window assembly600 is mounted, for example. With fixed connector 630 being electricallycoupled to a window controller, the optical state of the electrochromicdevice of IGU 610 may be changed.

While floating connector 620 and fixed connector 630 as shown in FIG. 6are pin/socket type connectors, other types of connectors may be used.For example, in some embodiments, a face of the nose of the floatingconnector may be flat and include magnetic pads presented on the face ofthe floating connector. Wires of wire assembly 617 may be coupled tothese magnetic pads. Fixed connector 630 may also include magnetic padsthat are configured or shaped for mechanical and electrical contact withthe pads of the floating connector. Alternatively, floating connector620 and fixed connector 630 may be similar to the connectors describedabove in relation to FIG. 5A.

Floating connector 620 may be attached to frame 605 with screws, nails,or other devices, or may be a compression fit with no additionalaffixing members. A nose of the floating connector may be flush with theouter edge of frame 605. The nose of the floating connector may becircular, rectangular, or other shape.

While wire assembly 617 is shown as being directly connected to floatingconnector 620, other mechanisms may be used to connect wire assembly 617to floating connector 620. For example, in some embodiments, theconnection of wire assembly 617 to floating connector 620 may be madewith connectors similar to the connectors described above in relation toFIG. 5A.

Further, similar to the connectors and the wire assembly described inFIG. 5A, floating connector 620, fixed connector 630, or the distal endof the wire assembly, of which the fixed connector 630 is a part, mayinclude a memory device and/or an integrated circuit device. The devicemay store information for identifying and/or controlling theelectrochromic pane in IGU 610, as described above.

In some embodiments, IGU 610 may include two electrochromic panes. Inthis embodiment, the floating connector may include four female socketsthat are electrically coupled to the bus bars of each of theelectrochromic panes (i.e., each electrochromic pane would include atleast two bus bars). Likewise, fixed connector 630 would include fourmale pins to be plugged into the floating connector.

FIG. 7 shows examples of schematic diagrams of a window unit, 700,incorporating an IGU including an electrochromic pane. Window unit 700includes a frame, 710, in which a fixed frame, 707, and a movable frame,705, are mounted. Fixed frame 707 may be fixedly mounted in frame 710 sothat it does not move. Movable frame 705 may be movably mounted in frame710 so that it may move from a closed position to an open position, forexample. In the window industry, the window unit may be referred to as asingle hung window, the fixed frame may be referred to as a fixed sash,and the movable frame may be referred to as a movable sash. Movableframe 705 may include an IGU (not shown) including an electrochromicpane (not shown), with connection of the electrochromic pane to a windowcontroller being provided by a floating connector, 715, and a fixedconnector, 720. While FIG. 7 shows a window unit including one movableframe with connectors for connecting the electrochromic pane of themovable frame to a window controller, the connectors also may be usedwith a window unit including two movable frames. Also, one of ordinaryskill in the art would appreciate that the described embodiments withone or two movable frames could include horizontally-sliding windows.

When movable frame 705 is in an open position, floating connector 715,affixed to the movable frame 705, may not be in contact with fixedconnector 720, which is affixed to the frame 710. Thus, when movableframe 705 is in an open position, the electrochromic pane of the IGUmounted in movable frame 705 may not be able to be controlled by awindow controller. When movable frame 705 is in a closed position,however, floating connector 715 makes contact with fixed connector 720.The mating of floating connector 715 and fixed connector 720 provideselectrical communication, and thus allows for actuation of theelectrochromic pane of the IGU in movable frame 705. For example, thefixed connector may be coupled to a window controller, with the windowcontroller being configured to transition the electrochromic pane of theIGU between a first optical state and a second optical state.

Floating connector 715 and fixed connector 720 are one example of a pairof connectors for electrically coupling an electrochromic pane to awindow controller. Other pairs of connectors are possible. Floatingconnector 715 has a flange, 716, and a nose, 717, extending from theflange. Nose 717 may have a length about equal to a thickness of movableframe 705. Nose 717 includes a terminal face, 718, that includes twoexposed female contacts, 719. Floating connector 715 may be affixed tomovable frame 715 through mounting holes 721 in the flange 716 usingscrews, nails, or other attachment devices and/or press fit (i.e.,secured by compression only). Because female contacts 719 of floatingconnector 715 may have opposite polarities, both floating connector 715and fixed connector 720 may have offset mounting holes and/or be shapedor configured so that they can be installed in only one way, e.g.,having an asymmetrical element associated with the shape of theconnector and/or a registration notch or pin. That is, for example, onemounting hole 721 in flange 716 may be located closer to nose 717 thananother mounting hole 721. With the mounting holes arranged in thisoffset manner, the exposed contacts may be arranged in a definedorientation when floating connector 715 is affixed to movable frame 705.For example, movable frame 705 may include holes that are drilled orformed in the movable frame when it is made. When installing the IGU inthe movable frame, one may mount floating connector 715 in movable frame705 such that offset holes 721 in flange 716 are arranged to match theholes pre-formed in movable frame 705. This offset arrangement ofmounting elements prevents the IGU from being connected to a windowcontroller incorrectly, which may damage the electrochromic pane of theIGU.

Another mechanism instead of, or in addition to, screws or nails may beused to affix floating connector 715 to movable frame 705. For example,in some implementations, nose 717 of floating connector 715 may furtherinclude protrusions. Such protrusions may engage with movable frame 705and hold nose 717 of floating connector 715 when the nose is passedthrough a hole or an aperture in the movable frame to expose terminalface 718 of nose 717. In some implementations, the protrusions from nose717 may be incompressible. The incompressible protrusions may engagewith and deform the inside of the hole or aperture in movable frame 705when nose 717 is passed through the hole during installation (e.g., thenose is partially inserted into the hole and then the remainder of thenose tapped in with a rubber mallet). When the incompressibleprotrusions engage with and deform inside the hole, they may holdfloating connector 715 in movable frame 705. In one example, theprotrusions are barbs or similar “one-way” protrusions that areconfigured to hold the nose in the aperture once inserted therein. Inanother example, the protrusions, although incompressible and configuredto hold the nose in the aperture, allow the nose to be removed with someamount of force that will not damage the connector. In otherimplementations, the protrusions from nose 717 may be compressible. Thecompressible protrusions may compressively engage with the inside of ahole or an aperture in movable frame 705 when nose 717 is inserted intothe hole. When the compressible protrusions engage with the hole, theymay hold floating connector 715 in movable frame 705.

Fixed connector 720 includes two male contacts 725. When movable frame705 is in a closed position, male contacts 725 of fixed connector 720contact the two female contacts 719 of floating connector 715. Thisallows electrical communication with the electrochromic pane in movableframe 705. Springs 727 or other mechanical devices are used to causemale contacts 725 to extend from the raised surface 726 of fixedconnector 720. Springs 727 or other mechanical devices also allow malecontacts 725 to recede into raised surface 726 of fixed connector 720when a force is applied to male contacts 725. Springs 727 in fixedconnector 720 may aid in protecting male contacts 725 during use ofwindow unit 700. For example, without springs 727, male contacts 725 maybe exposed and otherwise damaged by a user opening and closing thewindow in some cases. Male contacts 725 are one type of pogo pinelectrical contact.

In some embodiments, terminal face 718 of floating connector 715 mayinclude a circumferential rim and an interior recessed region whereexposed female contacts 719 are presented. The circumferential rim mayhave a slope directed inwardly towards the interior recessed region. Theinwardly directed slope of the circumferential rim may facilitate matingof raised surface 726 of fixed connector 720 with terminal face 718 offloating connector 715. Raised surface 726 may aid in guiding malecontacts 725 of fixed connector 720 to register with female contacts 719of floating connector 715.

Similar to floating connector 715, fixed connector 720 may be affixed toframe 710 through mounting holes 728 in fixed connector 720 usingscrews, nails, or other attachment devices. Fixed connector 720 also mayhave offset mounting holes. That is, for example, one mounting hole,728, in fixed connector 720 may be located closer to raised surface 726than another mounting hole, 728. With the mounting holes arranged inthis offset manner, male contacts 725 may be arranged in a definedorientation when fixed connector 720 is affixed to frame 710. Forexample, frame 710 may include holes that are drilled or formed in theframe when it is made. An installer of fixed connector 720 in frame 710may mount the fixed connector to the frame such that offset holes 728are arranged to match the holes formed in the frame. This prevents theIGU from being connected to a window controller incorrectly, which maydamage the electrochromic pane of the IGU.

In this example, mounting holes 728 in fixed connector 720 also allowfor movement of fixed connector 720, that is, fixed connector 720 ismovably affixed to frame 710. For example, each of mounting holes 728includes an open volume around the screw that passes through it. Thisopen volume may be a slot that allows fixed connector 720 to translateorthogonally (in the plane of the page as drawn) to the motion ofmovable frame 705 in order to align with floating connector 715 whenmovable frame 715 moves towards a closed position and thereby connectors715 and 720 “dock” with each other. The slot is sized so that the headsof the attaching screws cannot pass through the slots, thus fixedconnector 720 is “slideably” attached to frame 710.

Fixed frame 707 of window unit 700 also may include an IGU (not shown)including an electrochromic pane (not shown). Connectors, such asconnectors 715 and 720 described above, may be used to connect theelectrochromic pane of fixed frame 707 to a window controller. A fixedconnector having springs 727, or other mechanical devices that mayprotect the male contacts 725, may not need to be used in the connectorsfor fixed frame 707, however, as fixed frame 707 may remain fixed andnot move from an open position to a closed position.

In some embodiments of a fixed connector and a floating connector for amovable frame mounted in a frame, springs or other mechanisms are notused to cause male contacts 725 to extend from raised surface 726 offixed connector 720. Instead, for example, a magnetic force is used tocause male contacts 725 of fixed connector 720 to couple with femalecontacts 719 of floating connector 715. The magnetic force may beprovided by either or both of female contacts 719 in floating connector715 and/or male contacts 725 in fixed connector 720 including magneticelements, for example. The magnetic elements may be neodymium magnets,for example. A magnetic force between male contacts 725 and femalecontacts 719 causes male contacts 725 to extend from raised surface 726and couple to female contacts 719 in floating connector 715 whenfloating connector 715 and fixed connector 720 are in close proximity toone another. When fixed connector 720 and floating connector 715 are adistance apart from one another, a mechanical device may impart a forceon male contacts 725 that causes male contacts 725 to recede into thefixed connector 720, for example, springs that cause male contacts 725to recede into fixed connector 720 when the magnetic force issufficiently diminished by separation of fixed connector 720 andfloating connector 715.

It should be noted that, as described thus far, when movable frame 705of window unit 700 is closed, electrical contact is made via thecontacts as described. In one embodiment, the movable frame containingthe IGU and the frame in which the movable frame resides have a wirelesspower generator and receiver. In this way, the electrochromic pane canbe transitioned even if the movable frame is in an open position. It isconvenient to have the wireless power generator in the frame and thereceiver in the movable frame containing the IGU and the electrochromicpane, but embodiments are not so limited. Wireless poweredelectrochromic windows are described in U.S. patent application Ser. No.12/971,576, filed Dec. 17, 2010, titled “Wireless Powered ElectrochromicWindows,” which is hereby incorporated by reference in its entirety. Inone embodiment, the frame contains a radio frequency (RF) generator fortransmitting wireless power and the movable frame contains a receiverfor transforming the wirelessly transmitted energy into electricalenergy to power the electrochromic pane. In another embodiment, one ormore wireless power generators are located away from the electrochromicpane while the receiver is in the movable frame. In other embodiments,magnetic induction is used to generate wireless power for theelectrochromic pane.

In other embodiments, continuous electrical contact between a frame anda movable frame mounted in the frame is made via connectors with slidingcontacts. FIG. 8 includes schematic diagrams of a window unit, 800,which includes IGUs each including an electrochromic pane. FIG. 8includes front views and a partial cross section of the window unit 800.Cross-section C (lower portion of FIG. 8) is indicated by line C on thefront view in the upper left portion of FIG. 8.

Window unit 800 includes a frame, 810, in which a first movable frame,805, and a second movable frame, 807, are mounted. First movable frame805 and second movable frame 807 are movably mounted in frame 810 sothat they both may move up and down in frame 810. In the windowindustry, window unit 800 may be referred to as a double hung window andmovable frames 805 and 807 may be referred to as movable sashes. Firstmovable frame 805 includes an IGU, 815, including an electrochromic pane(not shown). Second movable frame, 807, includes an IGU 817 including anelectrochromic pane (not shown).

To provide electrical connections to the electrochromic panes in each ofIGUs 815 and 817, frame 810 includes rails (e.g., two rails for each ofmovable frames 805 and 807, and additional rails for communication toonboard circuitry if included in the IGU) that are electrically coupledto a window controller when the sashes are installed in frame 810. Inthis example, each of IGUs 815 and 817 include a floating connector,825, that electrically connects the bus bars (not shown) of theelectrochromic panes to connector pins 835 mounted in movable frames 805and 807, respectively. Springs 830 or other mechanisms may be associatedwith connector pins 835 to force connector pins 835 into contact withrails 820 when movable frames 805 and 807 are mounted in frame 810. Notethat rails 820 need not, and in this example do not, traverse the entireheight of frame 810. This is due to the positioning of connectors 825mounted in movable frames 805 and 807. By virtue of this placement,electrical connection between pins 835 and rails 820 is maintainedthroughout the entire slidable range of the movable frames. In someembodiments, rails 820 traverse the entire height of the frame 810,depending on the positioning of connectors 825 in each of the movableframes 805 and 807.

In some embodiments, rails 820 may be a metal. In other embodiments,rails 820 may be carbon or other conductive material, e.g., carbonbrushes or woven carbon fibers, e.g., in the form of a compressibletube. In some embodiments, connector pins 835 may be a metal or carbon.Connector pins 835 may also be in the form of brushes. In someembodiments, the interface between rails 820 and connector pins 835 mayserve as a weather seal. Further, the motion of movable frames 805 and807 in frame 810 may serve to clean the surfaces where rails 820 contactconnector pins 835 so that electrical contact may be maintained.

Other configurations of rails 820 and connector pins 835 are possible.For example, the rails may be positioned at 837 where a movable framecontacts frame 810. Pins 835 or other conductive surface may be arrangedto contact rails 820 positioned at 837.

While FIG. 8 shows a window unit including two movable frames withconnectors for connecting the electrochromic panes of the movable framesto a window controller, the connectors also may be used with a windowunit including one movable frame or horizontally sliding windows.

In some embodiments of IGU 815 or 817, the IGU may include twoelectrochromic panes. In this embodiment, to provide electricalconnections to the electrochromic panes in each of IGUs 815 and 817,frame 810 may include rails (e.g., four rails for each of the moveableframes 805 and 807, as each electrochromic pane would include at leasttwo bus bars). The rails in the frame may be electrically coupled to awindow controller. In one embodiment, the four rails for each movableframe are configured as two pairs, each pair on opposite sides of themovable frame so as to avoid contact due to any play the movable framemay have in the frame in which it resides. In another embodiment, thefour (or more) rails associated with each IGU are on the same side ofthe movable frame, substantially parallel but spaced apart sufficientlyso as to avoid contact with another rail's floating connector contacts.Another way to maintain continuous electrical communication between amovable frame mounted in a frame is by direct wiring. Embodimentsdescribed herein use flexible wiring, e.g. ribbon cable, to make theelectrical connections.

FIG. 9A shows a schematic diagram of an IGU 900 including anelectrochromic pane 505 and an associated ribbon cable 905. The IGU 900includes an electrochromic pane, 505, having bus bars, 515, which are inelectrical communication with an electrochromic device, 517 (for anexemplary cross-section see FIG. 2). Electrochromic pane 505 is matchedwith another pane (not shown) and attached to the other pane with aseparator, 520 (indicated by the dotted lines). Outside of separator 520is a secondary sealing area. Wires 522 and 523 are connected to bus bars515 and extend through IGU 900 to a connector, 902. Connector 902 iscapable of being connected to a ribbon cable, 905. Ribbon cable 905 maybe connected to a window controller, 910. In some embodiments, theribbon cable may be a cable with many conducting wires running parallelto each other on the same plane. The ends of the ribbon cable mayinclude connectors for connecting to connector 902 and to windowcontroller 910.

In some embodiments, connector 902 may be similar to connector 525(i.e., connector 902 may include one or more ferromagnetic elements) andribbon cable 905 also may include one or more ferromagnetic elements forengaging connector 902 with ribbon cable 905. Other mechanisms also maybe used to engage connector 902 with ribbon cable 905.

In some embodiments, connector 902 may include a memory device and/or anintegrated circuit device. Ribbon cable 905 may include more wires orelectrically conductive paths than the two paths needed to electricallyconnect to bus bars 515 of electrochromic pane 505 so that the windowcontroller can communicate with the memory device and/or the integratedcircuit device. In some embodiments, the ribbon cable may haveelectrically conductive paths for controlling more than oneelectrochromic pane, as described below. Ribbon cables have advantagesincluding the capability of having multiple parallel wires for carryingpower, communication signals etc., in a thin, flexible format.

In some embodiments, IGU 900 includes two or more electrochromic panes.Connector 902 may be capable of providing electrical contact to the busbars of each of the electrochromic panes (i.e., each electrochromic panewould include at least two bus bars). Thus, in the example of an IGUhaving two electrochromic panes, the ribbon cable may include fourconducting wires running parallel to each other on the same plane forpowering the electrochromic panes.

As described above, in certain embodiments, an IGU may include more thanone connector. In one embodiment, a second connector or furtherconnectors are redundant and serve the same function as the firstconnector, such as for facilitating installation of the IGU by providingmore flexibility in wiring configurations to the IGU. In otherembodiments, the second or further connectors are for connecting the IGUto other IGUs in series or in parallel. In one example, the IGUs arelinked via connectors and wiring assemblies in order to function, forexample, independently, according to the commands of a singlecontroller. The controller may also include capability to controlphysical movement of one or more of the IGUs via a movement mechanism.The movement mechanism can include, e.g., components to open or close awindow which includes an IGU, and/or components for positioning afolding assembly containing two or more IGUs in windows and/or doors. Anillustration of this is depicted in FIG. 9B, which shows a systemincluding a plurality of IGUs, in this case four IGUs, 900 a-d,incorporated into a folding door system, 903. In this example, system903 includes four doors, each containing an IGU, 900 a-d, respectively.The system could include more or less doors and/or IGUs and may includewindows as well as doors. The IGUs of system 903 are each independentlycontrolled by a controller 910, e.g., as indicated in FIG. 9B by IGU 900b being in a colored state while IGUs 900 a, 900 c, and 900 d aretransitioned to a bleached state.

System 903 may be used, for example, in a large conference room as anoptional divider when the room is to be bifurcated into two smallerconference rooms. As indicated in the top view (FIG. 9B, lowerschematic) the doors containing IGUs 900 a-d are hinged in order to foldin an accordion fashion and also to translate (as indicated by the heavydashed arrow), e.g., into a recess in a wall for storage. In thisexample, controller 910 controls not only the independent transitioningof IGUs 900 a-d, but also the folding/unfolding of the doors as well asthe translation of the doors into the storage position. The mechanism(s)for folding and translating the doors is not depicted in FIG. 9B;however, one of ordinary skill in the art would appreciate that suchmechanisms may be commercially available and well known. The mechanismsmay include components that require powering via one or more of thedoors, and thus the electrical communication in such instances may passthrough wiring assemblies, such as ribbon cable assemblies 905 betweenIGUs 900 a-d, but this is not necessary. In some embodiments, acontroller controls not only the transition of an electrochromic device(i.e., the electrochromic device associated with an IGU), but also,independently, an associated movement of the IGU via a movementmechanism(s).

Referring back to FIG. 9B, controller 910 can accept input manually asdepicted and/or wirelessly (e.g., via a remote control device).Controller 910 is in electrical communication with each of IGUs 900 a-dvia ribbon cable assemblies, 905. In this example, each of IGUs 900b-900 d has two connectors, e.g., IGU 900 d is connected both tocontroller 910 and to IGU 900 c via ribbon cables 905 and correspondingconnectors in IGU 900 d. In turn, each of IGUs 900 b and 900 c alsocontain two connectors to which ribbon cables 905 are connected in orderto continue the chain of electrical communication. The IGU 900 a has atleast one connector in order to electrically connect to IGU 900 b viaribbon cable 905. The IGU 900 a may also have additional connectors,e.g., if it is convenient to produce IGU 900 a in the same manner asIGUs 900 b-d, but this is optional, as in this example IGU 900 a needonly have one associated connector.

In this example, independent control of the electrochromic panes in IGUs900 a-d is accomplished by connecting the IGUs to the window controllerin series. Each of ribbon cables 905 has an appropriate number of wiresand associated contacts to accommodate electrical communication, andthus independent control, from controller 910. In certain embodiments,the ribbon cable may include any number of different wires, depending onthe IGUs to be controlled, the window controller specifications, themanner in which the IGUs are coupled and, optionally, sensors and alsoany associated movement mechanisms that must be controlled via theelectrical communication lines through the IGUs. In some embodiments,the ribbon cable may include 4, 8, 18, 24, or even more wires. Forexample, the ribbon cable may include two wires if a number of IGUs arecoupled to one another in series and there are not any sensorsassociated with the IGUs. As another example, the ribbon cable mayinclude four wires if two IGUs are coupled to one another and both IGUsare directly coupled to a window controller.

FIG. 9C shows an example of a window unit, 915, incorporating an IGU,900, including an electrochromic pane. Window unit 915 includes a frame,920, in which a movable frame, 925, which holds an IGU 900, is mounted.Movable frame 925 may be movably mounted in frame 920 so that it mayrotate along an axis of rotation, 917, from a closed position to an openposition, for example. In the window industry, window unit 915 may bereferred to as a casement window and frame 920 may be referred to as ahinged sash. Movable frame 925 may include IGU 900 including anelectrochromic pane (not shown), with electrical connection of theelectrochromic pane to a window controller being provided through aribbon cable, 905. Ribbon cable 905 may allow for rotation of movableframe 925 with respect to frame 920. In some cases, the windowcontroller may not only control the optical transitions of IGU 900, butalso, optionally, control a movement mechanism for the window to openand close and related intermediate positioning.

In the illustrated example, ribbon cable 905 includes two maleconnectors, 907 and 909, for coupling IGU 900 in movable frame 925 to awindow controller coupled to frame 920. Many other different types ofconnectors may be used for a ribbon cable, however. For example, in someother embodiments, the ribbon cable may include a male connector and afemale connector, two female connectors, and/or a connector includingone or more ferromagnetic elements as described herein.

In some embodiments, the ribbon cable may be a commercially availableribbon cable, and in some embodiments, the ribbon cable may be aspecially fabricated ribbon cable having specific connectors. The ribboncable may include any number of different wires, depending on the IGU900 and the window controller. For example, the ribbon cable may includeup to 4, 8, 18, 24, or even more wires. Two wires may be used to connecta window controller to the bus bars of the electrochromic pane, and thefurther wires may be used to connect the window controller to sensors,for example, associated with the IGU 900. FIG. 9C depicts a rathersimple window movement mechanism, i.e., rotating on an axis in order toopen and close. There are more complicated movement mechanisms for whichcontrollers described herein may control and for which moresophisticated wiring assemblies are configured. Some of these arefurther described below.

FIG. 9D shows schematic diagrams of a window unit, 930, incorporating anIGU, 900, including an electrochromic pane (not specifically depicted).Window unit 930 includes a frame, 932, in which a movable frame, 935, ismounted. Movable frame 935 is movably mounted in frame 932 so that itmay rotate and translate via a movement mechanism, 937, from a closedposition to an open position, for example. Although shown with threearms, mechanism 937 may include any number of arms that allow for thisrotation and translation. In this example, movement mechanism 937 is amanually operated mechanism, but in other embodiments, the mechanism isdriven electrically and, optionally, the controller that controls thetransitions of the electrochromic pane(s) in the IGU 900 also controlsmovement mechanism 937 for a prescribed rotation and translation.

The electrochromic pane(s) of the IGU 900 is in electrical communicationwith a window controller through a ribbon cable, 940. By virtue of itsconfiguration, ribbon cable 940 allows for rotation and translation ofmovable frame 935, with respect to frame 932, without becoming entangledin mechanism 937 and also while being aesthetically unobtrusive (i.e. itis at least partially hidden to the user by mechanism 937). Ribbon cable940 may include two connectors 941 and 943, similar to ribbon cable 905,for coupling the electrochromic pane in IGU 900 in movable frame 935 toa window controller, e.g. via wiring through frame 932. Again, manydifferent types of connectors may be used for the ribbon cable 940. Insome embodiments, ribbon cable 940 may be partially or fully attached toan arm or arms of mechanism 937. Ribbon cable 940 may be attached to anarm of movement mechanism 937 with an adhesive, 945, for example. Otherways of attaching the ribbon cable to a component of mechanism 937 arepossible, however, including brackets, clips and Velcro, for example. Asshown, ribbon cable 940 may include one or more folds such that itconforms to accommodate the configuration of mechanism 937. For example,ribbon cable 940 may include the folds shown in the two illustrations inFIG. 9D, right-most portion. Ribbon cables are well suited for suchapplications because they are relatively flat and can be folded withoutbreaking the wires within the ribbon.

In certain embodiments, a ribbon cable similar to the ribbon cable 905or 940 is used for a window or door unit including a movable frame thattranslates, which is typically referred to as a “slider” in the windowand door industry. In these embodiments, the slider unit (also called asliding door assembly) may comprise a fixed outer frame and a movablewindow or door frame sliding coupled within the fixed outer frame. Theslider further comprises a fixed window or door frame, which is mountedto the fixed outer frame. The movable frame may include an IGU includinga pane with an optical device such as an electrochromic pane. Themovable frame may be movably coupled within the fixed outer frame sothat it may translate, generally, but not necessarily, in a horizontaltranslation. For example, a “double hung” window could also beconsidered a slider in this context, and thus would be configured forvertical translation. A ribbon cable allows for translation of themovable frame with respect to the fixed frame, while maintainingelectrical communication between a controller and the optical device inthe movable door or window.

FIG. 9E depicts a schematic including an embodiment of a sliding doorassembly, 950. Assembly 950 includes a fixed door, 900 f, and a movabledoor, 900 m. Movable door 900 m is slideably engaged with a guide, 955,e.g., a track in which a skate connected to movable door 900 m can movewithin guide 955. Guide 955 includes a slot, 960, which allows a portionof a ribbon cable 952 (for clarity, the ribbon cable 952 and connector965 components are shown only in detail in the bottom portion of FIG.9E) to pass unobstructed during translation of movable door 900 m. Inthis rendering, the front face of guide 955 is depicted as removed toreveal slot 960. In this example, movable door 900 m may travel parallelto fixed door 900 f, as indicated by the long dotted arrow above doors900 f and 900 m. In other embodiments, movable door 900 m, withappropriate configurational modifications to guide 955, may also travelorthogonally to a plane parallel to the doors, as indicated by the smalldotted arrow near the bottom left corner of movable door 900 m in theupper portion of FIG. 9E. For example, like doors common in Europe, themovable door 900 m may also translate “in” and “out” orthogonally to thepath parallel to the fixed door (or wall), such that the two doors aresubstantially in the same plane when the slider unit is closed, andparallel and adjacent when the slider unit is open. During this “in” and“out” motion, the face of movable door 900 m may be parallel to thefixed door (or wall if there is only one door), or it may be at anangle, where one end, e.g. the top or bottom end, of the door translatesin or out but the other end remains substantially in the same position,thus “tilting” doors are contemplated. In some of these embodiments with“in” and “out” motion, guide 955 may also have an additional slot (notdepicted), e.g., in the (front) side depicted as open to reveal slot960, and a portion of the base and top, to allow ribbon cable 952 todisengage with the guide 955 and travel outward with the movable door900 m. In one embodiment, there is also a mechanism to ensure that themovable door 900 m can only tilt back along substantially the same pathso that the cable must pass back through the additional slot in order toagain be positioned within slot 960.

The bottom portion of FIG. 9E shows further detail, including ribboncable 952 a portion of which passes through slot 960. A major portion ofribbon cable 952 resides inside a recess of the guide 955, which may be,e.g., a rectangular channel, having slot 960 at the base and running thelength of the channel. Near the end portion of the ribbon cable 952 thatconnects to movable door 900 m, a fold is made in ribbon cable 952 sothat the cable's flat portion can run parallel to (as indicated by thedotted arrow) and translate through slot 960 when movable door 900 m istranslated. A connector, 965, at this end of ribbon cable 952, such as,for example, a pin connector (e.g., 5-pin connector) as describedherein, engages with a socket, 970, in order to deliver power andcommunications to the EC device(s) or other optically switchabledevice(s) in movable door 900 m. Appropriate clips, clamps and the likemay be used to ensure the fold in ribbon cable 952 remains and that theportion of ribbon cable 952 that traverses slot 960 (from inside guide955 to outside and under in this case, guide 955) does not rub againstthe edges of slot 960. Guide 955 may support the weight of movable door900 m via a skate or other mechanism; there may be a mechanism (notshown), e.g., rollers, under movable door 900 m, or both. Movable door900 m may be driven by an electric drive, which also may be part of thewindow control system, 910. In one embodiment, the face of ribbon cable952 is configured substantially horizontal inside guide 960. In anotherembodiment, the face of ribbon cable 952 is configured substantiallyvertical inside guide 960. It has been found that ribbon cable 952, byvirtue of is inherently serpentine and flexible nature, remains insidethe body of guide 955 and does not pass through slot 960 when orientedvertically. That is, the bottom edge of the major portion of ribboncable 952 may rest on the base of guide 955 during translation ofmovable door 900 m and not pass through slot 960 because the serpentinenature of the ribbon cable ensures that its bottom edge only crossesslot 960, it does not align parallel with the slot and therefore fallthrough slot 960. Thus the portion of ribbon cable 952 that passesthrough slot 960 in order to engage with connector 965 is the onlyportion that passes through slot 960. Because of this, and therelatively light and robust construction of the ribbon cable, generallyvery little, if any, wear to the ribbon cable occurs, as a result ofusing the slider mechanism.

In one embodiment, the ribbon cable exits the guide through one of theends of the guide. For example, as depicted in FIG. 9E, ribbon cable 952exits channel 955 at the end distal to movable door 900 m, and isconfigured appropriately in the wall, and connects to controller 910.The other end of ribbon cable 952 bears a connector, similar if not thesame as connector 965, in order to connect with controller 910.

FIG. 9F is a schematic drawing depicting an embodiment including asliding door assembly, 950 a, comprising an electrical connectionsystem. Although this example and others are described with reference toa movable door, a movable window may be used. Sliding door assembly 950a comprises a fixed door, 900 f, and a movable door, 900 m. Movable door900 m is slideably engaged with a guide, 955, e.g., a track in which ashuttle, 980, slideably connected to movable door 900 m, can move withinguide 955. Guide 955 includes a lengthwise slot, 960, which allows aportion of a ribbon cable 955 (for clarity, the ribbon cable 955 andconnector 965 components are shown only in detail in the bottom portionof FIG. 9F) to pass unobstructed during translation of movable door 900m. In the top portion of FIG. 9F, the front face and top of guide 955are depicted as removed to reveal slot 960. In this example, movabledoor 900 m may travel parallel to fixed door 900 f, as indicated by thelong dotted arrow above doors 900 f and 900 m. In other embodiments,movable door 900 m, with appropriate configurational modifications toguide 955, may also travel orthogonally to a plane parallel to thedoors, as indicated by the small dotted arrow near the bottom leftcorner of door 900 m in the upper portion of FIG. 9F. For example, likedoors common in Europe, the movable door 900 m may also translate “in”and “out” orthogonally to the path parallel to the fixed door (or wall),such that the two doors are substantially in the same plane when movabledoor 900 m is closed, parallel and adjacent when movable door 900 m isopen. During this “in” and “out” motion, the face of movable door 900 mmay be parallel to the fixed door (or wall if there is only one door),or it may be at an angle, where one end, e.g. the top or bottom end, ofthe door translates in or out but the other end remains substantially inthe same position, thus “tilting” doors are contemplated. In some ofthese embodiments, guide 955 may also have an additional slot (notdepicted), e.g., in the (front) side depicted as open to reveal slot960, and a portion of the base and top, to allow ribbon cable 952, alongwith shuttle 980, to disengage with the guide 955 and travel outwardwith the movable door 900 m. In one embodiment, there is also amechanism to ensure that the movable door 900 m can only tilt back alongsubstantially the same path so that the cable and shuttle 980 must passback through the additional slot in order to again be positioned withinslot 960 of guide 955. During movement of the sliding door or window,the one or more wires are configured with the other components of themovable door 900 m to try to avoid interaction of the one or more wireswith the guide and/or with the moving components of the sliding doorassembly, 950 a. In this case, the interaction being avoided may referto, for example, the one or more wires contacting and located betweentwo or more moving components, or the one or more wires contacting theguide and/or contacting one or more moving components.

The bottom portion of FIG. 9F shows further detail, including a ribboncable, 952, a portion of which passes through shuttle 980 in order todeliver power and communications to the EC device(s) or other opticallyswitchable device(s) in movable door 900 m. A major portion of ribboncable 952 resides in a recess inside guide 955. The guide 955 may be,for example, a rectangular channel and the ribbon cable 952 may residewithin the recess of the rectangular channel section. The guide 955comprises a slot 960 at the base and running the length of the channel.In this illustrated example, ribbon cable 952 is electrically connectedto a connector cable, 972, which includes a connector for mating with aconnector of ribbon cable 952. The connector cable 972 goes to a roundcable having five wires that terminates in a 5-pin connector (not shown)for mating with the connector (e.g., a pigtail connector) at an end theIGU wiring to the bus bars of the EC device(s) or to other opticallyswitchable device(s) of the movable door 900 m. In other embodiments,the connector cable 972 connects directly to ribbon cable 952. Connectorcable similar to connector cable 972 may also be used at the other endof ribbon cable 952 after it exits guide 955, and/or may also be usedwithin guide 955 and then exits guide 955.

Referring to the detailed, lower portion of FIG. 9F, only the rear sideof slot 960 is depicted so that details of a shuttle, 980, are shown.Near an end portion of the ribbon cable 952 that connects to the movabledoor 900 m, shuttle 980 includes a horizontal top surface onto which aportion of a flexible tape, 975, is affixed. Ribbon cable 952 is affixedto flexible tape 975. Ribbon cable 952 is affixed to the top surface ofthe portion of the flexible tape 975 that is affixed to the top ofshuttle 980. Flexible tape 975 is bent back forming a bend portion,along a curve (indicated by the curved double headed arrow). Thisbending allows flexible tape 975 and the ribbon cable 952 affixedthereon to pass back over itself and reside substantially parallel toitself and to the top surface of guide 955 where it is affixed, e.g., atthe distal end of guide 955. In addition, this bending allows theflexible tape 975 and the ribbon cable 952 affixed thereon to extendinside guide 955 and parallel to the top surface of guide 955. Thusribbon cable 952 is affixed to the underside of that portion of flexibletape 975 (as indicated by the dotted lines). Ribbon cable 952 extendsalong the top surface of shuttle 980, and a fold is made in cable 952 sothat a portion of the ribbon cable's flat portion is substantiallyvertical to pass through a vertical channel 981 in shuttle 980 andthrough an aperture in a base plate, 965, for shuttle 980. Base plate965 is affixed to door 900 m e.g., via a screw (depicted) and a tab,966, that inserts into a portion of movable door 900 m in order tosecure that end of base plate 965. A cover, 985, may be used to securethe vertical portion of ribbon cable 952 that passes through thevertical channel 981 in the body of the shuttle 980. In this illustratedexample, a vertical portion of the shuttle body with vertical channel981 passes through an aperture in base plate 965, so that shuttle 980can be moved vertically within the aperture for ease in installing theshuttle 980 into slot 960 of guide 955 (e.g. guide 955 is open on theend so that shuttle 980 may be inserted into slot 960 and then an endcap installed on guide 955).

The body of shuttle 980 is configured to couple to movable door 900 mand slideably engage with slot 960 in guide 955. A top portion of thebody of shuttle 980 prevents shuttle 980 from passing verticallydownward through slot 960, and a bottom portion of the body of shuttle980 prevents shuttle 980 from passing vertically upward through theaperture in base plate 965 affixed to movable door 900 m. In this way,shuttle 980 may slideably engage with movable door 900 m while movementof the shuttle 980 in the vertical direction may be restricted. The bodyof the shuttle 980 is also configured to slideably engage within slot960 to slide in the horizontal direction. That is, while engaged withmovable door 900 m, the shuttle 990 may slide in the horizontaldirection within the slot 960. Shuttle 980 may be constructed of aplastic material so as to slide easily within slot 960, but sturdyenough to support the weight of movable door 900 m.

In another embodiment, the sliding door assembly 950 a may compriseanother shuttle, similar to shuttle 980, at the opposite top end ofmovable door 900 m that also resides in slot 960. This other “dummy”shuttle need not make any contact with the ribbon cable 952, but rathermay serve as an additional support for the weight of movable door 900 mand as a sliding mechanism for the movable door 900 m. In this case, thefirst shuttle 980 may not need to support the full weight of movabledoor 900 m, or may support little to no weight of movable door 900 m.

Referring back to FIG. 9F, after passing through the vertical channel981 in shuttle 980, ribbon cable 952 is folded back on itself so as passthrough a guide slot, 986, on the underside of base plate 965. Ribboncable 952 may pass through a horizontal channel in the bottom portion ofshuttle 980 that prevents shuttle 980 from passing vertically throughthe aperture in base plate 965. Thus the ribbon cable is protected frominteraction between the underside of base plate 965 and shuttle 980.Ribbon cable 952 is also protected by virtue of being affixed toflexible tape 975, which may be, e.g., a curved spring steel tape,similar to those used for tape measures. In other embodiments, thematerial used for the ribbon cable 952 may be sufficiently rigid, yetflexible, (e.g., similar to a curved spring steel tape) such thatflexible tape 975 is not needed. In other embodiments, an energy chainis used to support wiring such as a ribbon cable 952, rather than aflexible tape. In such embodiments, the mechanisms are substantially thesame, but ribbon cable 952 may be substituted for standard wires as theenergy chain will both protect and support the wire(s) within its body.Energy chains are commercially available, e.g., in plastic form, byIgus, Inc. of Providence R.I. Although flexible tape 975 is used in thisexample, other flexible members may be used.

In one embodiment, the ribbon cable exits the guide through one of theends of the guide. For example, as depicted in FIG. 9F, ribbon cable 952may exit guide 955 at an end distal to movable door 900 m, which isconfigured appropriately in the wall, and ribbon cable 952. The distalend of ribbon cable 952 bears a connector, which may be similar if notthe same as connector 965 (shown in FIG. 9E). The connector is used toconnect with a controller 910, which is electrically connected to apower source, or to connect directly with a power source.

Certain embodiments pertain to a ribbon cable connection system for asliding door or window. The ribbon cable connection system comprises aguide, the guide is configured to house a ribbon cable, wherein a firstportion of the ribbon cable exits the guide through a slot in the guide.The first portion of the ribbon cable is configured to traverse alongand within the slot during translation of a connector when the connectoris affixed to the sliding door or window. In one embodiment, the slot isat the base of the guide. In one embodiment, the guide is a rectangularchannel. In one embodiment, the guide further includes an aperture atone end for the ribbon cable to exit the guide. In one embodiment, theguide is configured to allow translation of the first portion of ribboncable both parallel with the length of the guide and also perpendicularto the length of the guide. In one embodiment, the sliding door orwindow includes a switchable optical device. In one embodiment, theswitchable optical device is an EC device. In one embodiment, thesliding door or window includes an alarm system. In some cases, a ribboncable comprises an over-molded jacket.

Systems and apparatus described herein for sliding door and/or windowapplications need not be mounted and the movable door/window movedhorizontally as, for example, depicted and described in relation toFIGS. 9E-9H. One of ordinary skill in the art would recognize that,e.g., vertically mounted, vertically moved and/or vertically orientedsystems and apparatus are also contemplated herein. Also although FIGS.9B-F describe apparatus that include a ribbon cable, embodiments where anon-ribbon type cable may be used are also contemplated. An example of acable management system for sliding windows and/or door applicationswith, e.g., a non-ribbon type cable is described in relation to FIGS. 9Gand 9H.

FIGS. 9G and 9H depict drawings of an embodiment including a cablemanagement system, 901. Referring to FIGS. 9G and 9H, cable managementsystem 901 can refer to a sliding IGU cable management system thatprovides a flexible connection for power and control to a movable dooror window. FIG. 9G is an exploded view drawing of cable managementsystem 901. FIG. 9H is a drawing of a perspective view of cablemanagement system 901 attached to a movable (sliding) door, 921. Cablemanagement system 901 is configured to guide movement of and protect anIGU connector cable, 918, as movable door 921 is opened and closed (asindicated by the heavy dashed arrows in FIG. 91H) e.g., past a fixeddoor 922. This is accomplished, in the embodiment depicted, using aconnector cable carrier 923 comprising a base bracket 913, a chain guide908, a cover plate, 911 and a frame bracket 906. The connector cablecarrier 923 is mounted on one end, using frame bracket 906 to the railor stile of the frame (door or window) of movable door 921, and on theother end, using base bracket 913, to an optional base rail, 914, thatis installed, typically, on a door header, 919, that provides connectionto an IGU controller (not shown).

A cover, also not shown, is typically installed over the connector cablecarrier 923 and base rail 914 to conceal the mechanism to the end user,for aesthetics, and to prevent users from interaction with the system.Although the base rail 914 is an optional, it may be desirable toinclude this feature in the cable management system 901 since it mayprotect the cable running from the door header 919 into connector cablecarrier 923.

In this illustrated example, connector cable carrier 923 includes achain guide, 908. Chain guide 908 may be made of plastic, for example.Chain guide 908 may connect frame bracket 906 to base bracket 913.Connector cable carrier 923 may include a recess or other feature thatcan house a portion (e.g., middle portion between two opposing ends) ofthe IGU connector cable, 918. As movable door 921 translates, chainguide 908 protects IGU connector cable 918 while flexing and allowingfree horizontal movement of the movable door 921. The IGU connectorcable 918, in this example, is a 5 wire shielded cable, with 5-pinconnectors at each end. A portion of IGU connector cable 918 protrudesfrom base bracket 913 for introduction into base rail 914 via anaperture in base rail 914. Base rail 914 is typically configured with aplurality of such apertures, as depicted in FIGS. 9G-9H, for flexibilityin installation applications. Although the IGU connector cable 918 isdepicted as a 5 wire shielded cable in the illustrated example, otherconnector cables, such as a ribbon cable, can be used.

In the illustrated example, the other end of IGU connector cable 918 isnested in a cavity of frame bracket 906. An optional cover plate, 911,may be used to enclose the cavity once the IGU connector cable 918 isconnected. Base rail 914 allows a cable from a window controller to runwithin the base rail 914 and connect to IGU connector cable 918.Although shown as a U-channel section, the base rail 914 could also be apipe or square channel or an angle stock, for example, where the cablerests on a horizontally configured side of the angle stock.

Although not shown, typically an IGU pigtail will emanate from anaperture in the door stile and pass through an aperture in mount 912,which is affixed to the door stile. That is, a cable from an IGUcontroller is run through base rail 914 where it connects with connectorcable 918 and the other end of connector cable 918 connects to an IGUpigtail. An optional spacer, 916, may be used between mount 912 andframe bracket 906 if needed. Connector cable carrier 923 allows movementof the movable door 921 while protecting IGU connector cable 918.

In certain embodiments, cable carrier 923 does not include chain guide,908. In one embodiment, a flexible cable conduit protects the IGUconnector cable running between frame bracket 906 and base bracket 913.The flexible cable conduit may or may not be attached to the framebracket 906 and/or the base bracket 913. In certain embodiments, theconnector cable 918 itself is the only component running between framebracket 906 and base bracket 913. In one embodiment, a ribbon cable withan over-molded jacket is used.

In certain embodiments, an electrical connection system of a slidingdoor assembly comprises a guide (e.g., 955) and a shuttle (e.g., 950).Although described with respect to a movable door, the electricalconnection system can be used with a movable window. The guide comprisesa recess within which pass one or more wires for electricalcommunication between at least a power source and an opticallyswitchable device in the sliding door or window. The guide furthercomprises a bottom surface and a lengthwise slot in the bottom surface.The shuttle is configured to couple to the movable door or window andslideably engage with the lengthwise slot in the guide, the shuttlefurther configured to pass the one or more wires from the sliding dooror window, through a body of the shuttle into the recess in the guide,wherein during movement of the sliding door or window, the one or morewires are protected from interaction with one or more moving components.In some cases, the electrical connection system further comprises aflexible member (e.g., (e.g., flexible tape 975 or chain guide 908)affixed at one end to the shuttle. In these cases, the one or more wiresmay be coupled to the flexible member and the flexible member comprisesa bend portion allowing the flexible member to pass back over itself andreside substantially parallel to the length of, and inside, the guide.In one case, the one or more wires are a ribbon cable and the flexiblemember is a spring steel tape. In another case, the flexible member is achain guide made of a non-electrically conducting material, and the oneor more wires reside within the body of the chain guide. In either ofthese cases, the shuttle may be slideably engaged with the sliding dooror window in the vertical direction. For example, a vertical portion ofa body of the shuttle may pass through an aperture in the base plateaffixed to the sliding door or window. In one case, the guide furthercomprises an open end so that the shuttle may be inserted into the slotthrough the open end of the guide during assembly of the electricalconnection system.

In certain embodiments, an electrical connection system of a slidingdoor assembly comprises a frame bracket (e.g., 906) and a base bracket(e.g., 913). The frame bracket may be configured to couple to thesliding door or window. The base bracket may be configured to couple toa header of the sliding window or door, or to a base rail. In theseembodiments, the frame bracket and base bracket are configured to houseopposing ends of an IGU connector cable (e.g., 918). In one embodiment,the IGU connector cable is a ribbon cable. In one example, the ribboncable may comprise an over-molded jacket. In another embodiment, amiddle portion of the IGU connector cable (i.e. a portion between theopposing ends) is housed with a flexible conduit between the framebracket and the base bracket. In another embodiment, the electricalconnection system further comprises a base rail (e.g., 914). In oneexample, the base rail may comprise a U-channel. In another example, thebase rail may comprise comprises one or more apertures, wherein at leastone aperture is configured to register with an aperture in the basebracket such that one end of the IGU connector cable passes through theaperture in the base bracket and the at least one aperture of the baserail. In another embodiment, the frame bracket comprises an aperture forreceiving an IGU pigtail into a recess of the frame bracket toelectrically connect to an end of the IGU connector cable housed withinthe recess. In one case, the aperture is in outer surface of the framebracket coupled to a frame of the sliding door or window and/or theframe bracket further comprises a separate mounting element for couplingto a frame of the sliding door or window. In some cases, the IGUconnector cable is a 5 wire cable. As described above, where a connectoris configured within an IGU may be important when considering where toattach wiring connectors to the IGU. Flexibility in attaching wiringassemblies to an IGU can significantly reduce wiring complexity andlength, and thus save considerable time and money, both for fabricatorsand installers. One embodiment is an electrical connection systemincluding a track, the track including two or more rails that provideelectrical communication, via wiring and bus bars, to the electrodes ofan electrochromic device of the IGU. The track is, e.g., embedded in thesecondary sealing area of the IGU. An associated connector engages therails and thereby makes electrical connection to the rails. Anon-limiting example of the track described above is described inrelation to FIGS. 10A and 10B.

FIGS. 10A and 10B depict aspects of an IGU, 1000, including a track,1025, and an associated connector, 1045. In this example, track 1025 isalso a spacer that may serve as both a secondary sealing element and anelectrical connector for an electrochromic pane of the IGU, although thesealing function is not necessary. In this description, “track” is usedas a short hand to describe a unitary structure, e.g. where a track isformed as part of a frame made of single material having a unitary body,or a “track” is a component of an equivalent structure having a “frame”where the track is a sub-structural component thereof, e.g. made of thesame or a different material. In other words a “track” is either astructural feature of a unitary body or frame, or a “track” is acomponent of a frame. In the context of this description, a frame may ormay not serve the function of a spacer or separator for an IGU. Forexample, track 1025 may reside in the secondary seal region of the IGUand also serve a sealing function as between itself and the glass panelsof the IGU, or track 1025 may simply be embedded in the secondary sealwithout also functioning as a sealing element itself.

FIG. 10A is a schematic diagram of IGU 1000 including an electrochromicpane, 1010. Electrochromic pane 1010 includes bus bars, 1015.Electrochromic pane 1010 is matched with another pane (not shown) andtogether the panes sandwich a separator, 1020, with a primary seal beingformed between separator 1020 and the inside surfaces of the panes alongwith an adhesive. In this example, track 1025 is used to form asecondary seal, similar to the primary seal formed between the glasspanes and separator 1020, with an adhesive between the inner surfaces ofthe glass panes and track 1025. Thus, in this example, the primary andsecondary seals are formed in the same fashion. Track 1025 addsadditional rigidity and strength to the IGU structure as well as asealing function. In certain embodiments, the track is embedded in atraditional secondary sealant without also serving as a sealing elementitself; in these embodiments, the track need not traverse the entireperimeter of the IGU.

Track 1025 also includes rails, in this example in the form of wires,1030 and 1035, which provide electrical communication to bus bars 1015via wires, 1017. That is, wires 1017 connect bus bars 1015 to wires 1030and 1035 in track 1025. Track 1025 is described further in relation toFIG. 10B. FIG. 10A, in the bottom portion, shows only track 1025.Included is an expanded view of a corner portion of track 1025, showingdetail of a channel in which reside wires 1030 and 1035. In thisexample, wires 1030 and 1035 run all the way around the channel of track1025. In other embodiments, wires 1030 and 1035 run only in a portion(e.g., one side, two sides, or three sides) of track 1025. The rails ofthe track may be other than wires, so long as they are conductivematerial, although wires are convenient because they are common andeasily configured in a track, e.g., track 1025 may be an extrudedplastic material into which wires may be molded, or the wires may beinserted into the track after extrusion or molding.

FIG. 10B shows a cross-section D, as indicated in FIG. 10A, of track1025 showing the details of wires 1030 and 1035 and finer detail oftrack 1025. Track 1025 may be a non-conducting material, such as anextruded polymer, for example, that holds wires 1030 and 1035 in place.In one example, track 1025 is made of an extruded plastic channeledmaterial. The channeled material is cut and formed, e.g., ultrasonicallywelded, to form a unitary body as depicted. As shown in FIG. 10B, wires1030 and 1035 are located within recesses in track 1025 and, in thisexample, each wire is insulated on three sides (due to thenon-conductive nature of the polymeric material which surrounds thewires on three sides). As mentioned, the wires may be inserted into therecesses after the track is fabricated. Track 1025 includes two slots orchannels, 1040 and 1050. Slot 1050 allows for electrical connection ofan electrical connector, e.g., from a window controller to IGU 1000.Wires 1017 from bus bars 1015 of the electrochromic pane 1010 may behoused in slot 1040. Wires 1017 may pass though the material of track1025, e.g., passing from slot 1040 through an aperture and into slot1050, so that the each of the wires 1017 may contact its respective wire1030 or 1035 (one wire 1017 depicted, aperture through track not shown).In this context, “wires” 1017 may be other means of electricalcommunication through the track's body, such as metal bars, tabs,shunts, and the like. The aperture through which wires 1017 pass may besealed prior to fabrication of the IGU, or during fabrication of theIGU, e.g., using adhesive sealant residing in slot 1040. In one example,a sealant is applied to the gap between the wire and the aperture. Whenmade of polymeric material, wires that lead from the bus bar to therails of the track may be formed in the molded polymer, so that they aresealed by virtue of being integrated into the polymeric material, e.g.cast into or included in an extrusion process.

Slot 1040 also may allow for additional wires and/or interconnections tobe made to the IGU as well as housing electrochromic controllercomponents. In one embodiment, slot 1040 houses electrochromiccontroller components. In one embodiment, the electrochromic controllercomponents are entirely housed in the track body, whether in slot 1040or not. In other embodiments, where no track is used, the electrochromiccontroller is housed in the spacer, at least in part, in someembodiments the electrochromic controller is wholly within the spacer(separator). Controller embodiments with relation to spacers aredescribed in more detail below.

In one example, track 1025 is assembled with wires 1017 being attachedto rails 1030 and 1035 prior to being attached to bus bars 1015. Thatis, one embodiment is a track including rails and wires connected to therails, the wires passing through the track such that the track, oncesandwiched between two panes of glass, optionally with an adhesivesealant, forms a hermetic seal. In one such embodiment, assembly of theIGU includes 1) attaching wires 1017 to the bus bars, and 2) thensimultaneously forming the primary and the secondary seal usingseparator 1020 and track 1025.

Electrical connections may be made to electrochromic pane 1010 withconnector 1045. Connector 1045 may include a non-conducting body 1047with two conducting tabs, 1055 and 1060. In this example, each of thetwo conducting tabs 1055 and 1060 is connected to a single incomingwire, 1075. Each of the single wires may be coupled to a connector, asdescribed herein, and ultimately connected to a window controller. Inthis example, to establish electrical connection, connector 1045 isinserted into slot 1050 and then twisted about 90 degrees so that eachof the conducting tabs, 1055 and 1060, makes contact with a wire, 1035and 1030, respectively. In some embodiments, to ensure that a correctwire is in contact with the correct tab, tabs 1055 and 1060 and therecesses housing wires 1030 and 1035 are asymmetrical. As shown in FIG.10B, tab 1060 is thicker than tab 1055. Further, the recess housing wire1030 is smaller than the recess housing wire 1035. Connector 1045 entersslot 1050 and then, by virtue of the configuration of the recesses andtabs, the connector can be turned only so that tab 1060 contacts wire1030 and tab 1055 contacts wire 1035. Varying tab thickness and recesssize is one way to help to insure that the connector 1045 is in contactwith the correct wires, but other mechanisms to achieve this are alsopossible.

In another embodiment, track 1025 is metal and the wires and/or rails ofthe system are insulated. Tabs 1055 and 1060 of connector 1045 areconfigured to penetrate the insulation on the rails or wires in order toestablish electrical connection. Track 1025 may be a hybrid ofmaterials, for example, a metal frame with a polymeric insert for theportion that houses the rails or wires 1030 and 1035. One of ordinaryskill in the art would appreciate that the rails must be insulated fromthe body of the track otherwise a short circuit would occur. There arevarious configurations in which to achieve this result. In anotherembodiment, the body of the frame portion is an electrically insulatingfoam material and the portion which houses the rails is a rigidpolymeric material. Spacers and/or frames described herein may also befabricated from fiber glass.

One embodiment is an electrical connection system for an IGU includingan optical device requiring electrical powering, the electricalconnection system including: a frame, the frame having a unitary bodyand including; a track including two or more rails, each of the two ormore rails in electrical communication with; a wire configured to passthrough the frame for connection to an electrical power distributioncomponent of the optical device; and a connector configured to establishelectrical connection to the two or more rails and supply electricalpower to each of the two or more rails. In one embodiment, the frameincludes an electrically insulating conductive polymeric material. Inone embodiment, the track includes an electrically insulating conductivepolymeric material and each of said two or more rails comprise copper.The electrical connection system can be configured for use as the onlyspacer for the IGU (i.e. a structural component that forms the primaryseal). In one embodiment, the connector is a twist-type connector thatfits into a recess in the track, and upon twisting, engages with the twoor more rails in order to establish electrical communication. Theoptical device may be an electrochromic device. In certain embodiments,the frame comprises at least some of the electrical components of acontroller configured to control the optical device. The electricalconnection system may be configured as a secondary sealing element inthe IGU.

One of ordinary skill in the art would appreciate that otherconfigurations of track 1025 are possible. For example, in oneembodiment, track 1025 is a linear track that is inserted along one sideof the IGU in the secondary sealing area. Depending upon the need, one,two, three or four such linear tracks, each along an independent side ofthe IGU, are installed in the IGU. In another embodiment, track 1025 isU-shaped, so that when installed in the secondary sealing area of theIGU, it allows electrical connection via at least three sides of theIGU.

As described above, in certain embodiments, track 1025 can itself serveas the IGU spacer (forming the primary seal), rather than as acomplimentary structure to a spacer as described above (serving as asecondary sealing element or not). When used as the only spacer, theframe of the track can be wider than a typical spacer for an IGU mightbe. That is, a conventional IGU spacer is approximately 6 millimeters inwidth (along the primary sealing surface). The spacers described herein,may be of conventional width or up to about two times to about two andone half times (about 2× to about 2.5×) that width. For example, spacersdescribed herein may be about 10 millimeters to about 25 millimeterswide, about 10 millimeters to about 15 millimeters wide, and in oneembodiment about 10 millimeters to about 12 millimeters wide. Thisadditional width may provide a greater margin of error in a sealingoperation compared to a conventional spacer. This provides a more robustseal between the spacer and the glass lites of the IGU. In certainembodiments, when wires for the bus bars run through the spacer itself,rather than through the primary seal, this makes for an even more robustprimary sealing area.

One embodiment is an electrical connection system for an IGU includingan optical device requiring electrical powering. The electricalconnection system includes a frame having a unitary body and including atrack including two or more rails. Each of the two or more rails is inelectrical communication with a wire configured to pass through theframe for connection to an electrical power distribution component ofthe optical device and with a connector configured to establishelectrical connection to the two or more rails and supply electricalpower to each of the two or more rails. The electrical powerdistribution component of the optical device may be a bus bar. In oneembodiment, the frame includes an electrically insulating conductivepolymeric material. In certain embodiments, the track includes anelectrically insulating conductive polymeric material and each of saidtwo or more rails include copper. In one embodiment, the connectionsystem is configured for use as the only spacer for the IGU. In oneembodiment, the connector is a twist-type connector that fits into arecess in the track, and upon twisting, engages with the two or morerails in order to establish electrical communication. The optical devicemay be an electrochromic device, a photovoltaic device, a suspendedparticle device, a liquid crystal device and the like. In oneembodiment, the frame includes at least some of the electricalcomponents of a controller configured to control the optical device. Inone embodiment the frame includes an onboard controller, e.g. asdescribed in U.S. Pat. No. 8,213,074. In certain embodiments, theelectrical connection system is configured to be used as a secondarysealing element in the IGU. In one embodiment, the electrical connectionsystem is configured to be used as a primary sealing element of the IGU.

Using track 1025 as a spacer for an IGU is one example of a “pre-wired”spacer embodiment. That is, wires can pass through the body of thespacer itself in order to make contact with bus bars, rather thanrunning between the spacer and the glass, through the primary seal.Moreover the length of the wires can run through the interior of thespacer, rather than around it in the secondary sealing area. These andother embodiments are described in more detail below. Certainembodiments are described in terms of electrochromic devices; however,other optical devices are applicable.

FIGS. 11A-E depict aspects of IGU wiring schemes, where the IGU includesan optical device, such as an electrochromic device. Certain embodimentsdescribed herein refer to a single optical device; however, anotherembodiment is where the IGU includes two or more optical devices.Electrical connection systems described herein include configurations topower one or more optical devices in a single IGU. Referring to FIG.11A, an IGU, 1100, is constructed by mating an electrochromic lite,1105, with a spacer, 1110, and a second lite, 1115. In this example, busbars (an electrical power distribution component of the electrochromicdevice on lite 1105) 1150 are configured outside spacer 1110 in thefinal construct. This is described in more detail in relation to FIG.11B.

FIG. 11B shows cross section X-X of IGU 1100. In this depiction,electrochromic lite 1105 is the lower lite and lite 1115 is the upperlite. Spacer 1110 is mated on opposite sides to the lites with anadhesive sealant, 1125, which defines the primary seal of the IGU, i.e.,the top and bottom (as depicted) surfaces of spacer 1110 define theprimary sealing area of the spacer. Once mated, there is a volume, 1140,defined within the IGU; typically this is filled with an inert gas orevacuated. The spacer may have desiccant inside (not shown). Outside theperimeter of spacer 1110, but typically not extending beyond the edgesof the glass lites, is a secondary sealant material, 1130, which definesthe secondary seal of the IGU. The electrochromic device, 1145, on lite1105 is a thin film coating, on the order of hundreds of nanometers upto a few microns thick. Bus bars 1150 supply electricity to coating1145, each to a different transparent conductive layer so as to create apotential across layers of device 1145 and thereby drive the opticaltransitions. In this example, the bus bars are outside the spacer, inthe secondary seal. If all the bus bars are outside the primary seal,then wiring to the bus bars does not involve nor is there a likelihoodthat, the wiring will interfere with the primary seal of the IGU.Embodiments described herein provide electrical powering systems todeliver electricity to the bus bars when they are either in the primaryseal and/or inside the sealed volume 1140 of the IGU. One of ordinaryskill in the art would appreciate that an IGU may have one bus bar inthe secondary seal and, e.g., a second bus bar in the primary seal or inthe sealed volume of the IGU. Embodiments include systems for deliveringpower to such configurations as well.

FIGS. 11C and 11D show that when the bus bar is within the primary seal,then, in conventional apparatus, wiring to the bus bar passes throughthe primary seal. This is depicted by the dotted arrow in the figures.If both lites have optical devices, then the risk of a compromisedprimary seal is doubled, because either the wiring for each lite passesthrough the primary seal proximate each lite, or the wiring for bothlites must pass through the primary seal proximate a single lite. FIG.11E shows that, e.g., the conductive ink (e.g. silver-based) used forbus bars can be used as a shunt, 1160, across the primary seal andwiring connected to the shunt. This may help maintain the integrity ofthe primary seal somewhat, but still there is an increased likelihood ofprimary seal failure due to this traversal of the primary seal by theink. That is, the primary seal is optimized for adhesion between thespacer and the material of the lite, e.g., glass. When a differentmaterial, such as wire or conductive ink is introduced, there may not beas good a seal. When this different material traverses the primary seal,there is a much greater likelihood that the primary seal will fail atthat region. FIG. 11E also shows that it is common for wiring to the busbars to run outside the spacer and within the secondary seal region to a“pigtail” connector 1165 which is a length of wire with a connector atthe end.

Embodiments described herein provide for electrical connection systemsfor IGUs. Particularly, described embodiments include “pre-wired”spacers, that supply electricity to the bus bars (or equivalent powertransfer components) of optical devices, when the bus bars are withinthe primary seal or within the sealed volume of the IGU. This allows formaintaining the integrity of the primary seal, as well as simplifyingfabrication of the IGU. One embodiment is a spacer for an IGU, thespacer configured to supply electricity to an optical device on a liteof the IGU, via one or more electrical power distribution components ofthe optical device, where at least one of said one or more electricalpower distribution components is either within the primary seal orwithin the sealed interior volume of the IGU, and where the electricitysupplied to said at least one of said one or more electrical powerdistribution components does not traverse the primary seal of the IGU.

FIG. 12A is a cross-sectional drawing depicting a pre-wired spacer,1200. Spacer 1200 has a wire, 1205, that passes through it. Wire 1205delivers electricity from an external component, 1210, which is in thesecondary seal (as depicted), outside the secondary seal, or which hasportions both inside and outside secondary seal. In this example, 1210is an electrical socket, into which a plug is configured to enter andthereby supply electricity to wire 1205. Wire 1205 is in electricalcommunication with bus bar 1150 (e.g. soldered to the bus bar). In oneembodiment, external component 1210 is track 1025 as described inrelation to FIGS. 10A and 10B, e.g., it surrounds spacer 1200 aboutsome, or all, of the perimeter of spacer 1200. In one embodiment, spacer1200's structure is itself analogous to track 1025, that is, it has atrack system for establishing electrical communication with the opticaldevice via wire (or wires) 1205. In the latter embodiment, there may beno secondary seal and spacer 1200 may be wider than a traditionalspacer, so that the primary seal is, e.g., double or more of the sealingarea of a conventional primary seal.

FIG. 12B shows spacer 1200 from a top view and incorporated into an IGU1215. In this example, spacer 1200 has wires that pass through the widthof the spacer. One of these wires, attached to bus bar 1150 a, is alsoattached to a connector, 1225, which makes electrical communication witha second wire that spans around the spacer, in the secondary sealregion, and to, in this example, an onboard controller, 1220. In someembodiments, connector 1225 is not necessary because a single wireconnects to bus bar 1150 a, passes through spacer 1200 and connects tocontroller 1220. Controller 1220 is also in electrical communicationwith bus bar 1150 b via the other wire that passes through the spacer.Pre-wired spacer 1200 has the advantage that during IGU fabrication, itcan be laid down and quickly soldered to the bus bars and connector1225, if present.

FIG. 12C shows a partial cross section of spacer 1200, showing that thespacer may be of a conventional construction, i.e., metal such asstainless steel or aluminum, with a wire passing through it. Seal 1230ensures that there is no gas leakage from the IGU sealed volume throughthe aperture through which the wire passes. Seal 1230 may be a rubbergrommet of sufficient tightness so as to seal as described or seal 1230may be a polymeric or epoxy sealant added after the wire is run throughthe apertures in the spacer. FIG. 12D shows spacer 1235, made of a foamor solid polymeric material. A good hermetic seal is achieved since thewire is cast into the spacer or the foam is blown or formed with thewire in it.

FIG. 13A depicts another IGU, 1305, having a pre-wired spacer 1300. Inthis example, the wires passing through spacer 1300 are almost entirelycontained within the body of the spacer. That is, the wire in electricalcommunication with bus bar 1150 a emanates from spacer 1300 only at itsends, to connect with bus bar 1150 a and to connect with externalcomponent 1310, respectively. In this example, the other wire thatpasses through spacer 1300 is shorter and passes more or less directlythrough spacer 1300 in order to make electrical connection to bus bar1150 b. Also, in this example, component 1310 is a socket. Socket 1310is configured to accept controller components, or an entire onboardcontroller. That is, in the latter embodiment, the controller is a “plugin” module. The IGU is constructed as depicted in FIG. 13A with socket1310 in the secondary seal. The controller (not depicted) is a plug inmodule that may or may not fit entirely within the secondary seal (notbeyond the edges of the IGU). In this manner, IGUs can be constructedindependently of onboard controllers, and the onboard controllers can beeasily upgraded and/or switched out of the IGU. This may avoid having toreplace an IGU that had an onboard controller permanently affixed to thesecondary sealing material. FIG. 13B depicts spacer 1300 where a pigtailconnector (rather than socket 1310) is used as the common end of thewires that pass through the spacer.

In one embodiment, a pre-wired spacer as described herein may alsoinclude a controller for at least one optical device of an IGU. Thecontroller may be exterior to the spacer, for ultimate configuration inthe secondary seal or outside the IGU, or the controller may be insidethe spacer itself. The spacer may be metal or a polymeric material, foamor solid.

One of ordinary skill in the art would appreciate that spacer 1300,being prewired, makes fabrication of the IGU much simpler. That is, oneneed only register the lites with the spacer, solder the wires to thebus bars and then seal the IGU. Depending upon which pre-wired spacer isused, one can then add the secondary sealing material, or not.

FIG. 14A depicts a pre-wired spacer, 1400. Spacer 1400 has a pigtailconnector as described herein, but rather than wires emanating from theinterior faces of the spacer, e.g. as spacer 1300 had, spacer 1400 hascontact pads, 1405, which are in electrical communication with the wiresinside the body of pre-wired spacer 1400. In one embodiment, thepre-wired spacer may be made of an electrically insulating material,such as a polymer, either solid or foam. The contact pads are metal,such as copper, but may include gold, silver or other metal for betterelectrical contact. Contact pads 1405 may be co-planar with the sealingsurface of pre-wired spacer 1400, extend beyond the sealing surface, orbe below the sealing surface, depending upon the need. Typically, butnot necessarily, the contact pads do not span the width of the sealingsurface of the spacer, so that there is at least some of the spacermaterial, e.g. on either side of the contact pad, to make a good sealwith the glass. The contact pads depicted here are singular and have agenerally rectangular shape, but this is not necessary. For example,there may be multiple contact pads configured to make contact with asingle bus bar, e.g., circular pads arranged linearly along one side ofthe spacer, and similar configurations of shapes along one side of thespacer.

FIG. 14B depicts fabrication of an IGU with pre-wired spacer 1400.Contact pads 1405 (not depicted, they are on the back side of spacer1400 as drawn) are registered with bus bars 1425 when the spacer isregistered with lites 1410 and 1415. Lite 1410 has an optical device,such as an electrochromic device, on the surface that mates with thesealing surface of spacer 1400. Upon mating the lites with the spacer,electrical communication is established between the contact pads and thebus bars. If adhesive sealant is used to form the IGU, then it isapplied in such a way so as not to come between (at least not entirely)the contact pad and the bus bars. In certain embodiments, the contactpads are configured so as to penetrate any sealant that comes betweenthe contact pad and the bus bar. For example, the contact pads may havea rough surface and/or protrusions that make good electrical contactwith the bus bars despite adhesive sealant coming between the twosurfaces during mating. In other embodiments, the spacer is made ofmetal, and the contact pads are electrically insulated from the spacerbody using an electrically insulating material.

In one embodiment, the pre-wired spacer is titanium and no adhesive isused to form the primary seal. That is, a hermetic seal is formed byfusing the titanium to the glass using high localized heat at theinterface of the glass and titanium. In one embodiment, this bonding isachieved with a laser irradiation through the glass lite to which thespacer is to be bonded. In one embodiment, a boron compound is appliedto the titanium spacer prior to laser irradiation. Titanium is used forcertain hermetic sealing embodiments due to the similar coefficient ofexpansion of titanium and glass, e.g. float glass. Hermetic sealing witha titanium spacer may be used whether or not contact pads are used tomake electrical connection to the bus bars.

As described above, certain pre-wired spacers described herein have atrack for establishing electrical communication between a connector,which mates with the track rails, and the optical device. FIG. 15depicts a pre-wired spacer, 1500, which has a track (like track 1025,see FIGS. 10A and 10B). This figure shows that the width, E, of thespacer can be as a conventional spacer or thicker, such as describedabove (up to 25 mm wide) in order to form a superior primary seal onsealing surfaces 1515 and 1520. In one embodiment, width E is betweenabout 10 mm and about 15 mm. Spacer 1500 has passage, 1505, similar tochannel 1040 of track 1025, through which wires that connect to therails (1030 and 1035) may pass. The wires may pass through to theinterior surface, 1510, of the spacer for soldering to bus bars, or maypass through to the sealing surfaces, 1515 and/or 1520 to contact padsfor electrical communication thereto. In one embodiment, the spacer ismade of an electrically insulating material, and rails 1030 and 1035 areun-insulated so that a connector, like connector 1045 (see FIG. 10B) canbe inserted and establish electrical communication without having topierce any insulation around the rails.

FIG. 16A is a cross-sectional perspective of another pre-wired spacer,1600, including electrical connection about the perimeter of the spacerand through-spacer wiring. In this example, spacer 1600 is hollow as aconventional spacer, but has a wire passing through it as describedabove. In one embodiment, the spacer is a foam, polymeric material orfiberglass as described herein. The wire may pass through to theinterior face, 1510 for soldering to a bus bar, or be connected tocontact pads on the sealing surfaces, 1515 and/or 1520 (depending on ifone or both lites bear optical devices). In this example, the (in thisexample, two) wires of the spacer are each connected to a flexibleelectrically conductive tape, 1605 or 1610. For example, each tape mayrepresent the polarity of applied across an electrochromic device on onelite of the IGU. The tape may be a metal tape, such as copper or othergood conductor. For example, tape 1610 is soldered or welded to ajunction, 1615, that both supports the tape and makes good electricalconnection to both tape 1610 and with the wire. During fabrication ofthe IGU, the tapes are embedded in the secondary sealant. For example,the tapes are installed, and then the secondary sealant is applied, e.g.using a tip to inject the sealant between and under the tapes, and thenover the tapes to encapsulate (and suspend) the tapes in the secondaryseal of the IGU. Electrical connection to the tapes is described in moredetail in relation to FIGS. 16B-D.

FIGS. 16B-C show aspects of a particular embodiment in accord with thepre-wired spacer described in relation to FIG. 16A. In this example, aspacer, 1620, has conductive tapes 1605 and 1610 (same as spacer 1600).In this example, there is electrical communication between tape 1610 anda contact pad, 1625, on sealing surface 1515 of spacer 1620. Referringto FIG. 16C, the tapes are embedded in the secondary seal as describedabove, in this example, about the entire perimeter of the IGU. In oneembodiment, the tapes span at least about 90% of the perimeter of theIGU. Electrical connection between a power source for the optical deviceand the tapes is made through a connector, 1630. Connector 1630 is a pinconnector, the pins of the connector are pushed through the secondarysealant and thereby establish electrical communication with tapes 1605and 1610 by touching or piercing them. In this example, the pins eachhave a wire connected to them from the power source and are barbed pinsso that they remain solidly in the secondary sealant and electricallyconnected to their respective tapes. Using this electrical connectionsystem, the installer can simply pierce the secondary seal, practicallyanywhere about the perimeter of the IGU (depending upon if there is alsoa controller embedded in the secondary seal and/or so as to avoidjunction 1615) with the pin connector and establish electricalcommunication. In this example the body of connector 1630 is relativelyflat or low profile so as not to take up too much space and also toavoid jarring loose by shearing forces when handling the IGU once theconnector is installed. Another advantage of this system is that if theinstaller decides that placement of the connector is unsatisfactory,e.g., she wants to establish electrical communication on the other sideof the IGU, she can simply cut the wires, cover the connector withelectrical tape or other insulating sealant, and apply another connectorwhere desired. If there is a controller in the secondary seal or to markwhere any junctions reside, there may be color coding or otherdistinguishing marks applied to the secondary seal to demark thatlocation so as not to apply the connector in that location.

FIG. 16D shows alternative piercing-type pin connectors in accord withthe embodiments described in relation to FIGS. 16A-C. Connector 1640 haspins without barbs. The advantage of this configuration is that theconnector pins may be inserted into the secondary sealant and removed,without damaging the conductor tapes, and reinserted at anotherlocation. Connector 1645 has multiple pins for establishing electricalconnection to each conductor tape. That is, there are more than one pinso that electrical communication with each tape is assured. When thepins pass through the secondary sealant, there may remain some of thesealant on the pins, which would interfere with electricalcommunication. The likelihood of completely blocking electricalcommunication is much lower, that is, the likelihood of establishinggood electrical communication is much higher, when there are more pinsto pierce a particular conductor tape. In any pin connector embodiment,the pins may be coated with gold, for example. Connector 1650 hasmultiple pins and uses ribbon cable rather than traditional wires. Incertain embodiments, the tape conductor system is used not only forelectrical communication, that is, to deliver electricity, but also forcommunication lines. There may be two, three, four, five or more tapesand corresponding pins for piercing the tapes and establishingelectrical communication.

One embodiment is a method of fabricating an IGU, the method includesregistering a pre-wired spacer to a first lite including an opticaldevice, registering a second lite with the pre-wired spacer and thefirst lite and affixing the pre-wired spacer to the first and secondlites. The second lite optionally includes a second optical device. Inone embodiment, the pre-wired spacer includes wires emanating from theinterior surface of the pre-wired spacer and the wires are soldered tobus bars of the optical device prior, and the second optical device ifpresent, prior to registering with the first or the second lite. Thepre-wired spacer may include one or more contact pads on its primarysealing surface or surfaces, the contact pads configured to establishelectrical communication with the optical device, the second opticaldevice if present, or bus bars thereon, upon affixing the pre-wiredspacer to the first and second lites. In one embodiment, affixing thepre-wired spacer to the first and second lites includes using anadhesive sealant between the sealing surfaces of the pre-wired spacerand the first and second lites. In another embodiment, affixing thepre-wired spacer to the first and second lites includes forming ahermetic metal-to-glass seal, where the pre-wired spacer includes ametal, at least on the sealing surfaces. The metal may be titanium.

In one embodiment, an onboard controller is embedded in the secondaryseal and a ribbon cable is embedded in the secondary seal. FIG. 17Adepicts an electrical connection system, 1700, where ribbon cable, 1710,is used in the secondary seal in conjunction with piercing-typeconnectors as described herein. A controller, 1705, is also embedded inthe secondary seal. Piercing type connectors are used to establishelectrical communication to the two or more, e.g. conductive tapes, ofthe ribbon cable, the connector having one or more pins for each tape(or wire) of the ribbon cable. This electrical connection system allowsflexibility in placement of the connector to the IGU.

FIG. 17B depicts an electrical connection system where ribbon cable,1715, is used in the secondary seal, and pin sockets, 1720, areconfigured in the secondary seal about the perimeter of the IGU. In thisembodiment, a pin connector (not shown) may be introduced into any oneof pin sockets 1720, as they are redundant to the system. The pinsockets may be of the locking tab type, where once engaged with the pinconnector, the tabs lock the union into place. The tabs may bemanipulated to allow disengagement of the pin connector from the socket.There is little chance of secondary sealant interfering with electricalcommunication as the pins and corresponding sockets are free ofsecondary sealant. Controller 1705 may also have a pin socket 1720. Inone embodiment, there is at least one pin socket on each side about theperimeter of the IGU. In certain embodiments, the controller is notembedded in the secondary seal; however, piercing and pin and sockettype connections are still suitable. These embodiments are described inmore detail below.

One embodiment is an electrical connection system of an IGU including anoptical device requiring electrical powering, the electrical connectionsystem including: a ribbon cable embedded in the secondary seal of theIGU and configured to supply electricity to the optical device; one ormore pin sockets, also in the secondary seal, and in electricalcommunication with the ribbon cable, said one or more pin socketsconfigured in redundant form, each of the one or more pin sockets havingthe same electrical communication capability with the optical device;and a pin connector configured to mate with each of the one or more pinsockets and deliver electricity to the optical device. In oneembodiment, the pin connector and each of the one or more pin socketsare configured to reversibly lock together when mated. In anotherembodiment, the electrical connection system further includes acontroller configured to control the optical device, the controller maybe also embedded in the secondary seal and include at least one of theone or more pin sockets. In one embodiment, the IGU includes at leastfour of said one or more pin sockets in the secondary seal, inclusive ofthe controller in the secondary seal, or if the controller is exteriorto the secondary seal. In certain embodiments, when the controller isexterior to the secondary seal, the controller includes the pinconnector. In one such embodiment, the pin connector is configured sothat when mated to one of the one or more pin sockets, the controller isadjacent the secondary seal of the IGU. In another such embodiment, thepin connector is attached to the controller via a second ribbon cable.This allows for configuring the controller in the framing system wherethe controller may or may not be adjacent the edge of the IGU. In any ofthe above embodiments, the controller's width may be configured so it isnot greater than the width of the IGU.

FIG. 18A depicts an electrochromic window controller, 1800, havingpiercing-type pin connectors as described herein. In this example, theelectrochromic controller is configured such that it is not thicker thanthe IGU, but this is not necessary. The controller may be attached tothe IGU, as depicted in FIG. 18B, at virtually any point about IGU 1810(as indicated by the heavy dotted line). Controller 1800 interfaces witha control pad and/or a network controller via a ribbon cable, in thisexample. Ribbon cables are convenient for this purpose as they can carrypower and communication lines while having a flat, low-profile whichaides in configuring the cable in framing systems for windows. In oneembodiment, controller 1800 does not use piercing type pins, but ratherpin and socket type connection to the IGU; i.e., where there are pinsockets embedded in the secondary seal about the perimeter of the IGU(as in FIG. 17B, but where the controller is exterior of the secondaryseal and plugs into one of the pin sockets via it's pin connector,either directly attached to the body of the controller or at the end ofa ribbon cable). Using pin sockets with locking tabs, the controller canbe securely attached to the IGU without further attachment means. Incertain embodiments, the controller is not thicker than the IGU on thatdimension; that is, when the controller is affixed to the IGU asdepicted in FIG. 18B, the faces or surfaces of the controller that aresubstantially parallel to the exterior major surfaces of the lites ofthe IGU do not extend beyond the major surfaces. In this way thecontroller can be accommodated more easily within the framing for theIGU. The controller may be long and thin, e.g. spanning about 6 to about15 inches in length, and thus may attach to the IGU secondary seal atmore than one region of the controller. Attachment to the secondary sealcan be both with pin connectors as described to establish electricalcommunication, as well as with anchors that are specifically configuredto attach to the secondary seal material solely for attachment purposes;that is, to affix the controller to the IGU but not to establishelectrical communication with the one or more ribbon cables. In oneembodiment the controller uses piercing pin-type connectors (that piercethe secondary seal material to make electrical contact to ribbon typeconductors) along with these anchors configured solely for anchoring thecontroller to the secondary seal material. The anchors can, for example,be configured so as to penetrate the secondary seal, e.g. in between theribbon conductors, or, e.g., through the ribbon conductors, but be madeof electrically insulating material so as not to establish electricalcommunication with the ribbon conductors. In one embodiment, the anchorsare barbed pins that do not penetrate the secondary seal deep enough toreach the ribbon conductors, for example.

One embodiment is an electrical connection system for an IGU includingan optical device requiring electrical powering, the electricalconnection system including: one or more ribbon conductors configured tobe embedded in the secondary seal of the IGU and supply electricity tothe optical device; and a pin connector configured to establishelectrical connection to said one or more ribbon conductors bypenetrating the secondary seal material and piercing the one or moreribbon conductors thereby establishing electrical communication with theone or more ribbon conductors. In one embodiment, the pin connectorincludes barbed pins configured to secure pin connector to the one ormore ribbon conductors. The one or more ribbon conductors may supplyelectricity to the optical device via wiring through the spacer of theIGU. In one embodiment, the spacer of the IGU comprises one or morecontact pads on the primary sealing surface of the spacer, said one ormore contact pads configured to establish electrical communication withone or more electrical power distribution components of the opticaldevice. The one or more electrical power distribution components of theoptical device may be bus bars. The pin connector may be a component ofa controller configured to control the optical device. In oneembodiment, the controller's width is not greater than the width of theIGU. In another embodiment, the one or more ribbon conductors areconfigured such that the controller can be affixed to the edge of theIGU about at least 90% of the perimeter of the IGU.

Although the foregoing embodiments have been described in some detail tofacilitate understanding, the described embodiments are to be consideredillustrative and not limiting. It will be apparent to one of ordinaryskill in the art that certain changes and modifications can be practicedwithin the scope of the appended claims.

What is claimed is:
 1. An electrical connection system for a slidingdoor or window, the system comprising: a) a frame bracket configured tocouple to the sliding door or window; and b) a base bracket configuredto couple to a header of the sliding window or door, or to a base rail;wherein the frame bracket and the base bracket are configured to houseopposing ends of an IGU connector cable.
 2. The electrical connectionsystem of claim 1, further comprising a chain guide configured to housea middle portion of the IGU connector cable between the frame bracketand the base bracket.
 3. The electrical connection system of claim 1,wherein the IGU connector cable is a ribbon cable.
 4. The electricalconnection system of claim 3, wherein the ribbon cable comprises anover-molded jacket.
 5. The electrical connection system of claim 1,wherein a middle portion of the IGU connector cable is housed within aflexible conduit between the frame bracket and the base bracket.
 6. Theelectrical connection system of claim 1, further comprising the baserail.
 7. The electrical connection system of claim 6, wherein the baserail comprises a U-channel.
 8. The electrical connection system of claim7, wherein the base rail comprises one or more apertures, wherein atleast one aperture is configured to register with an aperture in thebase bracket such that one end of the IGU connector cable passes throughthe aperture in the base bracket and the at least one aperture of thebase rail.
 9. The electrical connection system of claim 1, wherein theframe bracket comprises an aperture for receiving an IGU pigtail into arecess of the frame bracket to electrically connect to an end of the IGUconnector cable housed within the recess.
 10. The electrical connectionsystem of claim 9, wherein the aperture is in an outer surface of theframe bracket coupled to a frame of the sliding door or window.
 11. Theelectrical connection system of claim 10, wherein the frame bracketfurther comprises a separate mounting element for coupling to a frame ofthe sliding door or window.
 12. The electrical connection system ofclaim 1, wherein the IGU connector cable is a 5 wire cable.